PROCESS MONITORING SYSTEM

Description

[0001] The present invention relates to a process monitoring system for monitoring an industrial process with a main sensor and at least one additional sensor separate from the main sensor.

[0002] Due to rising energy costs, for example, for compressed air, electricity, industrial gases, and / or water, more and more industrial processes are being monitored using sensors. These sensors can then be used, for example, to monitor compressed air consumption and, in particular, to detect leaks in the compressed air lines.

[0003] Due to the increasing number of sensors in industrial processes, the challenge is to enable easy integration of such sensors or consumption meters into existing data processing systems.

[0004] Typically, programmable logic controllers (PLCs) are used for this purpose. They receive measurement data from the individual sensors, consolidate it, and forward it to computer systems, for example, for data analysis. Due to this infrastructure, many different components must be installed and maintained, such as the programmable logic controller itself or the power supply for the programmable logic controller. In addition, there is the development effort required to program the programmable logic controller. These additional components and the additional development effort incur costs, require time, and require space, and are therefore disadvantageous.

[0005] US 2019 / 0271578 A1 describes a sensor device for monitoring containers.

[0006] US 2011 / 023153 A1 describes a wireless sensor network in which a local wireless network serves a large number of sensor nodes.

[0007] DE 20 2009 012 733 U1 describes a level sensor with a connection for data exchange and power supply.

[0008] It is therefore the object underlying the invention to provide a process monitoring system which enables a simple and cost-effective connection of sensors for monitoring an industrial process.

[0009] This object is achieved by a process monitoring system according to claim 1.

[0010] The process monitoring system according to the invention serves to monitor an industrial process. The process monitoring system comprises a main sensor and at least one additional sensor separate from the main sensor. Furthermore, the process monitoring system comprises a data evaluation unit separate from the sensors. The main sensor and the additional sensor are designed to acquire measurement data that preferably reflect the state of the industrial process. The main sensor is coupled to the additional sensor via a first data connection and designed to receive the measurement data from the additional sensor via the first data connection. The main sensor is further coupled to the data evaluation unit via a second data connection and designed to transmit its own measurement data and the measurement data from the additional sensor to the data evaluation unit via the second data connection.

[0011] The invention is based on the realization that the existing main sensor can be used not only to transmit its own measurement data to the data evaluation unit, but can also be used to receive the measurement data from the additional sensor and forward it to the data evaluation unit (e.g., a cloud). This eliminates the need for a PLC, whose sole purpose, for example, is to receive the measurement data from the additional sensor and forward it to the data evaluation unit. It goes without saying that the main sensor must have sufficient resources to receive and forward the measurement data.

[0012] In the following, we will generally refer to only one additional sensor. However, it is also possible for the main sensor to be linked to several additional sensors via data connections, receiving the measurement data from the multiple additional sensors and transmitting it to the data evaluation unit. The explanations contained herein regarding one additional sensor apply accordingly to a multitude of additional sensors.

[0013] In other words, the main sensor is connected to the auxiliary sensor via the first data connection and receives the auxiliary sensor's measurement data. The main sensor can then convert the auxiliary sensor's measurement data so that it can be transmitted to the data evaluation unit. For this purpose, the main sensor is connected to the data evaluation unit via the second data connection and can transmit both its own measurement data and the measurement data from the auxiliary sensor to the data evaluation unit.

[0014] Advantageous further developments of the invention can be found in the description, the figures and the dependent claims.

[0015] According to a first embodiment, the first and second data connections on the main sensor comprise different hardware interfaces. The main sensor can therefore comprise a first hardware interface for the first data connection and a second hardware interface, different from the first hardware interface, for the second data connection. In particular, the hardware interfaces are not compatible with each other. For example, the main sensor can receive the measurement data from the additional sensor in a specific data format, whereby the main sensor can change the data format in such a way that transmission to the data evaluation unit is possible.

[0016] According to the invention, the first data connection is designed to transmit measurement data by means of pulse sequences. The first data connection (and / or the associated hardware interface of the main sensor) comprises, in particular, an S0 pulse interface. Transmission by means of a pulse sequence does not place high demands on the additional sensor, which is why such data transmission can also be integrated into small and inexpensive sensors. The pulse sequence can be transmitted, in particular, electrically, via electrical cables, or optically, for example, via an infrared signal. The main sensor can accordingly have an electrical connection and / or an infrared interface as a hardware interface for the first data connection. The electrical connection can be, for example, a multi-pin plug with a screw thread. The infrared interface can, for example,It can be attached directly to the main sensor housing using a magnetic mount. Furthermore, the hardware interface for the first (and / or second) data connection can comprise a fiber optic cable with a corresponding slot in the main sensor housing. The measurement data can be transmitted via the fiber optic cable, for example, via optical Ethernet.

[0017] The SO-pulse interface, in particular, is often integrated into simple energy, volume, and / or water meters. This interface uses electrical pulses of, for example, 30 V or 27 V for data transmission.

[0018] In particular, there may be a direct, in particular electrical, data connection between the additional sensor and the main sensor, for example the aforementioned electrical line, so that the measurement data can arrive at the main sensor in pulse-coded form.

[0019] When using pulse sequences, the number of pulses per unit can be specified, in particular by a user. For example, 800 pulses can each correspond to one kilowatt hour (kWh). Alternatively, 400 pulses can each correspond to one standard cubic meter. In addition, the user can set the starting value and / or the unit (kilowatt hour, cubic meter, degrees Celsius, and the like) of the respective measurement data from the additional sensor connected to a specific hardware interface, in particular in the main sensor. In the main sensor, the measurement data received from the additional sensor can be treated internally as a process variable (i.e. like a measured value from the main sensor itself) and, in particular, ultimately made available to the data evaluation unit.

[0020] In addition to the SO-Puls interface, data transmission also takes place via M-Bus (also called Meter-Bus) or Smart Message Language (SML). Other data transmission methods are also possible. It is understood that these alternative or additional data transmission methods are to be considered as an alternative or additional method whenever the SO-Puls interface is mentioned herein.

[0021] According to an alternative embodiment, which is not covered by the claims, the first data connection comprises a gateway to which the additional sensor is connected, wherein the main sensor is configured to receive and / or retrieve the measurement data of the additional sensor from the gateway. The gateway can be connected to the main sensor via the first data connection. A plurality of additional sensors can, in turn, be connected to the gateway, wherein the main sensor receives and / or retrieves the measurement data of some or all of the additional sensors from the gateway. In this case, there is no direct data connection between the additional sensor and the main sensor.

[0022] According to a further embodiment, which is not covered by the claims, the additional sensor is designed to transmit its measurement data to the gateway using pulse sequences, in particular using an SO pulse interface, wherein the gateway and the main sensor are connected to each other via a first data connection configured as an Ethernet connection. The above statements regarding the transmission of measurement data using pulse sequences between the additional sensor and the main sensor apply accordingly to the transmission of measurement data to the gateway using pulse sequences.

[0023] The gateway can, in particular, be an S0 gateway, which converts the measurement data received via pulse sequences to an Ethernet connection, so that the measurement data can be transmitted to the main sensor via the Ethernet connection. A client can be run on the main sensor to retrieve or retrieve the measurement data from the gateway and transmit it to the main sensor.

[0024] According to a further embodiment, the second data connection is an Ethernet connection. The main sensor can comprise an Ethernet interface as a hardware interface for this purpose. If, according to an embodiment not covered by the claims, communication with the gateway is also via Ethernet, the main sensor does not need to have two different hardware interfaces, but can, in particular, comprise only one Ethernet interface, via which the first data connection to the gateway and the second data connection to the data evaluation unit are established.

[0025] The Ethernet connections mentioned here can, in particular, be Ethernet connections with power transmission (Power over Ethernet, PoE). The sensors can thus be supplied with electrical energy via the Ethernet connections.

[0026] The main sensor can transmit its own measurement data and the measurement data of the additional sensor(s) to the data evaluation unit via Ethernet via the Ethernet connection, using, for example, an Ethernet-based fieldbus, the HTTP or HTTPs protocol, a web server, the MQTT (Message Queuing Telemetry Transport) protocol, or OPC UA (Open Platform Communications Unified Architecture).

[0027] Because the main sensor provides both its own measurement data and the measurement data of the additional sensor to the data evaluation unit, the main sensor can be configured to integrate and / or embed the measurement data of the additional sensor into its own data model. This simplifies the provision of the measurement data to the data evaluation unit. Another advantage of implementing the process monitoring system is that only a single data endpoint (namely the main sensor) needs to be configured for the data evaluation unit, from which all measurement data can be retrieved / received. This eliminates the need for separate communication settings of the data evaluation unit for each additional sensor.

[0028] According to a further embodiment, the main sensor has a computing device configured to run a web server, wherein the computing device is additionally configured to transmit the measurement data from the main sensor and the additional sensor to the data evaluation unit. The web server can enable the display of the measurement data from both the main sensor and the additional sensor. The computing device, which is therefore already provided in the main sensor, can then also be used to transmit the measurement data from the main sensor and the additional sensor to the data evaluation unit. Before transmission, calculations can be performed on the measurement data and / or adaptations of the transmission format by the computing device. The web server can be accessed, for example, via the HTTP or HTTPs protocol via the first and / or second data connection.

[0029] It is understood that the main sensor may include a computing device even if the main sensor cannot run a web server.

[0030] According to a further embodiment, the main sensor, the additional sensor, and the data evaluation unit are arranged spatially separated from one another and are, in particular, each integrated in separate housings. The main sensor, the additional sensor, and the data evaluation unit can thus be independent devices, whereby the main sensor and / or the additional sensor can be designed, for example, as field devices. The main sensor and the additional sensor can, in particular, be arranged several meters apart. Even greater distances, for example, several hundred meters or several kilometers, can exist between the main sensor and the data evaluation unit.

[0031] According to a further embodiment, the main sensor and the additional sensor are designed to detect different physical quantities as measurement data. The sensors therefore detect different measurement parameters.

[0032] According to one embodiment, the main sensor can be a flow sensor, which is preferably a thermal flow meter, in particular for compressed air. The main sensor can therefore operate according to the calorimetric principle. The main sensor can comprise a heated sensor probe. The medium flowing past the sensor probe cools the sensor probe, whereby the temperature drop can be proportional to the flow velocity. The temperature drop can thus be used to determine the volume flowing through the main sensor, for example, of compressed air.

[0033] According to another embodiment, the additional sensor is an electricity meter or a water meter. The additional sensor can, for example, monitor how much electrical energy a consumer has required in the industrial process or what volume of water or another liquid has been consumed in the industrial process. The measurement data from the additional sensor, for example, the amount of electrical energy or water consumed, can then be transmitted to the main sensor via the first data connection at regular intervals (e.g., every 5, 10, 30, or 60 seconds).

[0034] According to a further embodiment, the data evaluation unit is formed by an edge computer or a cloud computer. The edge computer can, for example, be a computer located near the sensors, e.g., in the same factory hall. The cloud computer can be located far away from the industrial process, e.g., in a server farm. The connection to the edge or cloud computer can be enabled via an Ethernet network, which implements the second data connection. The data evaluation unit can receive the measurement data from the various sensors, perform calculations on it, evaluate the measurement data, and / or forward it to a process or management system.

[0035] The invention further relates to a sensor, referred to here as the "main sensor" according to the above explanations, for a process monitoring system for monitoring an industrial process. The main sensor is configured to acquire measurement data. The main sensor can be coupled to an additional sensor via a first data connection and is configured to receive measurement data from the additional sensor via the first data connection. Furthermore, the main sensor can be coupled to a data evaluation unit via a second data connection and is configured to transmit its own measurement data and the measurement data from the additional sensor to the data evaluation unit via the second data connection.

[0036] The invention further relates to a method for monitoring an industrial process with a main sensor and at least one additional sensor separate from the main sensor, wherein the main sensor and the additional sensor each acquire measurement data. The main sensor is coupled to the additional sensor via a first data connection and receives the measurement data from the additional sensor via the first data connection. The main sensor is coupled to a data evaluation unit via a second data connection and transmits its own measurement data and the measurement data from the additional sensor to the data evaluation unit via the second data connection.

[0037] The statements regarding the process monitoring system according to the invention apply accordingly to the main sensor according to the invention and the method according to the invention. This applies in particular with regard to advantages and preferred embodiments. Furthermore, it is understood that all features and embodiments mentioned herein can be combined with one another, unless explicitly stated otherwise.

[0038] The invention is described below purely by way of example with reference to the drawings. They show: Fig. 1 shows a first embodiment of a process monitoring system; and Fig. 2 shows a second embodiment of a process monitoring system.

[0039] Fig. 1shows a process monitoring system 10 with a main sensor 12 designed as a flow sensor for compressed air. The main sensor 12 is connected to a first auxiliary sensor 14 and a second auxiliary sensor 16. The first auxiliary sensor 14 is an electrical meter, whereas the second auxiliary sensor 16 is a water meter.

[0040] The sensors 12, 14, 16 monitor an industrial process (not shown), wherein, for example, the main sensor 12 has a passage for compressed air in which a heated sensor probe is arranged.

[0041] The additional sensors 14, 16 are connected to the main sensor 12 via SO-Puls interfaces 18. The SO-Puls interfaces thus form the first data connection mentioned above.

[0042] The main sensor 12 includes a second data connection in the form of an Ethernet connection 20, which connects the main sensor 12 to an Ethernet network 22. A data evaluation unit is connected to the Ethernet network 22, which includes a cloud data evaluation 24 and / or an edge data evaluation 26.

[0043] During operation of the process monitoring system 10, the additional sensors 14, 16 regularly transmit measurement data to the main sensor 12 via the SO-Puls interface 18. The main sensor 12 then converts the measurement data from the additional sensors 14, 16 such that the measurement data can be transmitted via the Ethernet connection 20 to the cloud data evaluation 24 and / or the edge data evaluation 26. In addition to the measurement data from the additional sensors 14, 16, the main sensor 12 also transmits its own measurement data to the cloud data evaluation 24 and / or the edge data evaluation 26.

[0044] Fig. 2shows an alternative embodiment of the process monitoring system 10. The embodiment according to Fig. 2 differs from the embodiment according to Fig. 1 in that the additional sensors 14, 16 are connected to a gateway 28 via the SO-Puls interfaces 18. The gateway 28 provides the measurement data from the additional sensors 14, 16 via an interface 30 for retrieval via the Ethernet connection 20. The main sensor 12 then retrieves the measurement data from the additional sensors 14, 16 from the gateway 28 via the interface 30 and transmits its own measurement data and / or the measurement data from the additional sensors 14, 16, as described above, to the cloud data evaluation 24 and / or the edge data evaluation 26.

[0045] In both embodiments, the need for an expensive and complex programmable logic controller to acquire the measurement data from the additional sensors 14, 16 can be avoided. Furthermore, the data evaluation unit 24, 26 only needs to communicate with the main sensor, providing a simple and cost-effective way of monitoring processes with a large number of sensors. List of reference symbols

[0046] 10Process monitoring system 12Main sensor 14First additional sensor 16Second additional sensor 18SO-Pulse interface 20Ethernet connection 22Ethernet network 24Cloud data evaluation 26Edge data evaluation 28Gateway 30Interface

Claims

1. A process monitoring system (10) for monitoring an industrial process, said process monitoring system (10) comprising a main sensor (12) and at least one additional sensor (14, 16) separate from the main sensor (12), wherein the process monitoring system (10) furthermore comprises a data evaluation unit (24, 26) separate from the sensors, wherein the main sensor (12) and the additional sensor (14, 16) are each configured to acquire measurement data, wherein the main sensor (12) is coupled to the additional sensor (14, 16) via a first data link (18) and is configured to receive the measurement data of the additional sensor (14, 16) via the first data link (18), wherein the main sensor (12) is coupled to the data evaluation unit (24, 26) via a second data link (20) and is configured to transmit its own measurement data and the measurement data of the additional sensor (14, 16) to the data evaluation unit (24, 26) via the second data link (20), characterized in that the first data link (18) is configured to transmit measurement data by means of pulse sequences and the first data link (18) comprises an S0 pulse interface (18) and a data transmission by means of M-Bus and / or by means of Smart Message Language.

2. A process monitoring system (10) according to claim 1, wherein the first and the second data link (20) comprise different hardware interfaces at the main sensor (12).

3. A process monitoring system (10) according to claim 1 or 2, wherein the second data link (20) is an Ethernet connection (20).

4. A process monitoring system (10) according to at least one of the preceding claims, wherein the main sensor (12) has a computing device which is configured to execute a web server, wherein the computing device is additionally configured to transmit the measurement data of the main sensor (12) and the additional sensor (14, 16) to the data evaluation unit (24, 26).

5. A process monitoring system (10) according to at least one of the preceding claims, wherein the main sensor (12), the additional sensor (14, 16), and the data evaluation unit (24, 26) are arranged spatially separately from one another and are in particular each integrated in separate housings.

6. A process monitoring system (10) according to at least one of the preceding claims, wherein the main sensor (12) and the additional sensor (14, 16) are configured to acquire mutually different physical variables as measurement data.

7. A process monitoring system (10) according to at least one of the preceding claims, wherein the main sensor (12) is a flow sensor, preferably a thermal flow meter, in particular for compressed air.

8. A process monitoring system (10) according to at least one of the preceding claims, wherein the additional sensor (14, 16) is an electricity meter or a water meter.

9. A process monitoring system (10) according to at least one of the preceding claims, wherein the data evaluation unit (24, 26) is formed by an edge computer or a cloud computer.

10. A main sensor (12) for a process monitoring system (10) for monitoring an industrial process, wherein the main sensor (12) is configured to acquire measurement data, wherein the main sensor (12) can be coupled to an additional sensor (14, 16) via a first data link (18) and is configured to receive measurement data of the additional sensor (14, 16) via the first data link (18), wherein the main sensor (12) can be coupled to a data evaluation unit (24, 26) via a second data link (20) and is configured to transmit its own measurement data and the measurement data of the additional sensor (14, 16) to the data evaluation unit (24, 26) via the second data link (20), characterized in that the first data link (18) is configured to transmit measurement data by means of pulse sequences and the first data link (18) comprises an S0 pulse interface (18) and a data transmission by means of M-Bus and / or by means of Smart Message Language.

11. A method for monitoring an industrial process using a main sensor (12) and at least one additional sensor (14, 16) separate from the main sensor (12), wherein the main sensor (12) and the additional sensor (14, 16) each acquire measurement data, wherein the main sensor (12) is coupled to the additional sensor (14, 16) via a first data link (18) and receives the measurement data of the additional sensor (14, 16) via the first data link (18), wherein the main sensor (12) is coupled to the data evaluation unit (24, 26) via a second data link (20) and transmits its own measurement data and the measurement data of the additional sensor (14, 16) to the data evaluation unit (24, 26) via the second data link (20), characterized in that the first data link (18) is configured to transmit measurement data by means of pulse sequences and the first data link (18) comprises an S0 pulse interface (18) and a data transmission by means of M-Bus and / or by means of Smart Message Language.