Method for supervising an industrial process

Abstract

A method for supervising an industrial process, the industrial process comprising a plurality of assets, the method comprising receiving asset state data representing at least one information on a state from at least one of the plurality of assets of the industrial process and generating at least one performance indicator based upon the asset state data; wherein the state is an automaton state from a discrete state space describing a service of at least one of the plurality of assets whereby the state is described by one and only one respective element of the discrete state space at any given point in time; and an industrial control system configured for supervising an industrial process.

Description

METHOD FOR SUPERVISING AN INDUSTRIAL PROCESSTECHNICAL FIELD

[0001] Embodiments of the present disclosure relate to a method for supervising an industrial process. Further embodiments relate to an industrial control system configured for supervising an industrial process. Particularly, methods and control systems according to the embodiments of the present disclosure may relate to mining processes.BACKGROUND

[0002] In industrial process supervision, performance indicators, often named Key Performance Indicators, KPI, are employed to monitor the performance of an industrial process, in particular of a process step or of an asset, exemplarily of machinery or of groups of machinery. Performance indicators can be calculated in industrial control systems, in particular in supervisory control systems. Common control systems calculate performance indicators based on measured values, and, in some cases, based on simulated values. This requires a calculation of the performance indicators that is tailored to the specific sources of the employed measured values. Further, measuring performance values of assets may be difficult, in particular in complex industrial processes that, exemplarily, comprise closed system assets or employ different communication interfaces. Therefore, a more structured method for supervising industrial processes comprising the generation of performance indicators is lacking.DISCLOSURE OF THE INVENTION

[0003] In the view of the foregoing, the present disclosure is directed to a method and an industrial control system for supervising an industrial process that comprises a state-based generation of performance indicators.

[0004] According to an aspect of the present disclosure, a method for supervising an industrial process is provided. The industrial process comprises a plurality of assets. The method comprises receiving asset state data representing at least one information on a statefrom at least one of the plurality of assets of the industrial process; and generating at least one performance indicator based upon the asset state data; wherein the state is an automaton state from a discrete state space describing a service of at least one of the plurality of assets. The automaton state is a state as used in Automata theory. The discrete state space comprises states that are described by discrete variables. Discrete variables may be Boolean or may comprise a countable set of numeric values.

[0005] According to another aspect of the present disclosure, an industrial control system configured for supervising an industrial process is provided. The industrial control system is configured for supervising the industrial process by any of the embodiments described in the present disclosure.INDUSTRIAL PROCESS

[0006] According to some embodiments of the present disclosure, the plurality of assets of the industrial process may comprise a plurality of equipment, in particular machinery, groups of machinery or infrastructure. In some embodiments, the plurality of assets may comprise mobile assets. Equipment may comprise mobile or immobile equipment. In particular, mobile equipment may comprise vehicles, exemplarily road vehicles, such as trucks, rail vehicles such as trains, airborne vehicles or seaborne vehicles. Mobile equipment may comprise shovels or conveyor belt systems. In a mining context, immobile equipment may comprise loading or unloading sites, trolley lines, crushers or mills. In some embodiments, an asset may comprise multiple separate assets, exemplarily a functional group of machinery may comprise multiple single pieces of machinery or an industrial plant may comprise a plurality of groups of machinery. In some embodiments, a person, in particular a worker, a supervisor or an operator, may be considered as an asset of the industrial process.

[0007] According to some embodiments, the industrial process may comprise a plurality of industrial sites, in particular a plurality of industrial sites situated at multiple locations. A single industrial site or a group of industrial sites may be considered as an asset of the industrial process.

[0008] According to some embodiments, the industrial process may be a mining process, in particular a surface mining process, exemplarily an open-pit mining process, or an underground mining process. The mining process may comprise excavating processes, transport processes and / or processing processes. In embodiments, the industrial process may be an oil- and / or gas-extraction process.ASSET STATE DATA

[0009] According to some embodiments of the present disclosure, the state of an asset may be an automaton state from a discrete state space describing a service of the asset. A service of the asset may comprise a property of the asset, in particular a service of the asset may be described as a service of the asset. The automaton state may be a state according to Automata theory. In particular, the state may be from a discrete state space. In some embodiments, the state may be described as either “true” or “false”.

[0010] In some embodiments, the asset state may comprise a general state describing a general property of the asset, exemplarily “in use”, “idle” or “waiting”. In embodiments, the asset state may comprise a specific state of the asset that may be relevant for a specific property or service, exemplarily “moving from place A to place B”. In some embodiments, the asset may execute at least one service at every specific moment in time. The at least one service may operate in asset states in order to report the progress of the service. In some embodiments, the service may be used to generate a performance indicator, in particular by receiving asset state data that may be associated with the service.

[0011] Exemplarily, in a mining industrial process, a truck may be the asset with exemplary services being loading, transportation, and maintenance. The truck may be in one of the services at any given moment in time. The asset state of the truck may be used to identify the service of the truck, in particular by associating specific asset state data with a specific service of the truck.

[0012] In some embodiments, the asset state data may be generated and / or stored in a standardized format, in particular in a format according to an industrial standard. The asset state data may be transmitted and / or received in a standardized format. In some embodiments, the asset state data may comprise information on the time at which the assetstate data is generated and / or the time duration for which a particular state has been determined.

[0013] In some embodiments, an asset, in particular a service of the asset, may comprise a state machine as described in VDI / VDE / NAMUR 2658 part 4. (2022). The state machine determines the state of an asset, in particular of a service of the asset. In embodiments, the state machine may determine values that may be required for generating the at least one performance indicator.RECEIVING ASSET STATE DATA

[0014] In some embodiments, the asset state data may be received at multiple points in time. In particular, the asset state may be received at regular points in time, exemplarily every second, every 10 seconds, every 30 seconds, every minute, every 5 minutes, every 15 minutes, every hour, every second hour, every 6 hours, every 12 hours or every day. In embodiments, the regular points in time, at which asset state data may be received, may be different for different assets.

[0015] In some embodiments, the asset state data may be received at specific points in time. In particular, the asset state data may be received when at least one performance indicator is generated. In embodiments, a user may request a generation of the at least one performance indicator and the asset state data relevant for the requested performance indicator may be received. In some embodiments, the asset state data may be received after the asset state changes. In particular, the asset state may change once a transition condition is met. The transition condition may comprise an end of a service of the asset, a change of a physical property of an asset or an external stimulus. In some embodiments the asset state data may only be received once a transition condition is met. This may result in a reduced amount of data to be received. In some embodiments, the asset state data may be received only once a data connection between the asset, in particular the state-machine of the asset, and the industrial control system is available. The asset state data may comprise a time stamp (e.g., a duration indicator representing the duration of a state).

[0016] In some embodiments, receiving the asset state data may comprise a communication based on a standardized communication interface. In particular, thestandardized communication interface may comprise an industrial standard communication interface, exemplarily based on module type packaging, MTP. This may allow to receive asset state data from assets from a plurality of manufacturers based on a standardized communication interface.PERFORMANCE INDICATORS

[0017] The at least one performance indicator may comprise performance indicators on a plurality of process levels. In particular, the at least one performance indicator may comprise performance indicators on an asset level, on a process level, on a service level, or on an industrial plant level.

[0018] The at least one performance indicator may comprise an availability indicator, a utilization indicator or an effectiveness indicator. The at least one performance indicator may be a generic indicator, that may particularly be employed for a plurality of assets, and that may be employed on a plurality of process levels. The at least one performance indicator may be a standardized indicator, in particular a performance indicator from an industrial standard, exemplarily from GMG standard “A Standardized Time Classification Framework for Mobile Equipment in Surface Mining” or from ISO standard 22400 “Automation systems and integration - Key performance indicators (KPIs) for manufacturing operations management”. The at least one performance indicator may comprise tailored indicators that describe a performance of a specific asset, of a specific service of the asset, of a specific industrial process or of a specific industrial site.

[0019] In some embodiments, availability indicators may comprise an uptime indicator, a physical availability indicator, or a mechanical availability indicator.

[0020] In some embodiments, utilization indicators may comprise use of availability indicators, asset utilization indicators, operating utilization indicators, or effective utilization indicators.

[0021] In some embodiments, effectiveness indicators may comprise operating efficiency indicators or production effectiveness indicators.

[0022] In some embodiments, the performance indicator may be based upon the at least one asset state data received at multiple points in time. In particular, the at least one asset state data may comprise a time of generation of the asset state data. Exemplarily, the performance indicator may be based upon asset state data received at multiple points in time, e.g., on a time series of past states, preferably including their times and / or durations. For example, the performance indicator may be a utilization indicator determined by comparing a time in which an asset is used with the overall time for which asset state data is received. In some embodiments, generating at least one performance indicator may comprise associating asset state data with time categories. Associating asset state data with time categories may comprise associating asset states with time categories. In some embodiments, generating performance indicators may comprise comparing received asset state data with scheduled asset states, in particular asset states obtained from production plans.

[0023] Time categories may comprise calendar time, scheduled time, unscheduled time, downtime, available time, standby time, operating time, operating delay, working time, nonproductive time or productive time.GENERATING PERFORMANCE INDICATORS

[0024] The performance indicators may be generated by an industrial control system. In some embodiments, the industrial control system may comprise a central infrastructure that receives the asset state data from the assets and generates, in particular calculates, the performance indicators based upon the received asset state data. In some embodiments, the industrial control system may comprise a distributed industrial control system. In particular, at least some asset state data may be received by distributed structures, exemplarily on the asset level, on the service level, on the process level, or on the industrial plant level.

[0025] In some embodiments, the performance indicators may be generated automatically. In particular, the performance indicators may be generated at regular points in time or upon receiving the required asset state data. In embodiments, the performance indicators may be generated upon a request from a user, a supervisor or an operator. In embodiments, the performance indicator is generated once at least one of the asset state data, upon which the performance indicator is based, changes.

[0026] In some embodiments, the performance indicators may be generated based upon values associated with a particular state or service. Exemplarily, a cost, a wear and tear value or an energy consumption may be associated with the service or asset state of an asset.

[0027] In embodiments, the performance indicators may be generated based on received asset state data and on simulated or estimated asset state data, in particular once received asset state data are not available. The simulated or estimated asset state data may be based on historical asset state data, planned asset state data or on asset state data of different assets.

[0028] In some embodiments, the performance indicators may be visualized to a user, in particular to a supervisor supervising the industrial process or to an operator operating at least part of the industrial process, exemplarily operating an asset.

[0029] In embodiments, visualizing the performance indicators may comprise visualizing the performance indicators on different levels of hierarchy of the industrial process. In particular, performance indicators may be visualized for the asset level, for the service level, for the process level and for the industrial plant level.

[0030] In some embodiments, visualizing the performance indicators may comprise providing a user interface configured for analyzing the performance indicators and for generating new performance indicators based upon the received asset state data.

[0031] In some embodiments, performance indicators may be aggregated from other performance indicators, in particular from performance indicators on a lower level of the hierarchy of the industrial process. Exemplarily, performance indicators for a service of an asset may be aggregated to generate performance indicators for the asset.

[0032] In some embodiments, the industrial process may be controlled based upon the at least one performance indicator. In particular, settings of the industrial process may be changed if a performance indicator is not within a range of acceptable values.

[0033] In some embodiments, the performance indicators may be employed to control machinery of the process, in particular machinery parameters, logistics of the process or a use of operators. In embodiments, the performance indicators may be employed to analyze the overall state of the asset, in particular to assess maintenance requirements, exemplarilyin the form of predictive maintenance. In embodiments, the performance indicators may be employed for benchmarking, in particular to compare different assets performing a similar or the same service. Exemplarily, mobile equipment with different drive technology may be compared. In embodiments, the performance indicators may be employed in decision making, in particular in determining better operational practices.BRIEF DESRICPTION OF THE DRAWINGS

[0034] The accompanying drawings relate to embodiments of the disclosure and are described in the following:FIG 1 schematically illustrates a method for supervising an industrial process according to embodiments described herein;FIG 2 schematically illustrates the method of FIG 1 in more detail with an additional optional step;FIG 3 schematically illustrates the method of FIG 1 in more detail with an additional optional step;FIG 4 schematically illustrates the method of FIG 1 in more detail.DETAILED DESCRIPTION OF EMBODIMENTS

[0035] Reference will now be made in detail to the various embodiments of the disclosure, one or more examples of which are illustrated in the figures. Generally, only the differences with respect to individual embodiments are described. Each example is provided by way of explanation of the disclosure and is not meant as a limitation of the disclosure. Further, features illustrated or described as part of one embodiment can be used on or in conjunction with other embodiments to yield a further embodiment. It is intended that the description includes such modifications and variations.

[0036] Fig 1 schematically illustrates a method 100 for supervising an industrial process 2 comprising a plurality of assets 1. In Fig. 1, the industrial process 2 comprises four assets 1. The method 100 comprises receiving 3 asset state data representing at least one information on an asset state from at least one of the plurality of assets 1 of the industrial process 2. The asset state data are received 3 by an industrial control system 10. In Fig. 1, the industrial control system 10 receives 3 asset state data from four assets 1. The industrial control system 10 generates 4 at least one performance indicator 20 based upon the asset state data received 3 from the assets 1 of the industrial process 2.

[0037] Fig. 2 schematically illustrates the method 100 of Fig. 1 in more detail and with an additional step. Each of the plurality of assets 1 of the industrial process 2 comprises at least one state machine 6. In Fig. 2, three of the plurality of assets 1 comprises one state machine 6 and one of the plurality of assets 1 comprises two state machines 6. The asset state data of the plurality of assets 1 is generated by the state machines 6. In particular, the state machines are defined to generate information on a service an asset 1 performs. The asset state data generated by the state machines 6 are received 3 by the industrial control system 10. The industrial control system 10 generates 4 at least one performance indicator 20 based upon the asset state data generated by the state machines 6. Generating 4 at least one performance indicator 20 based upon the asset state data generated by the state machine 6 may comprise associating the state machines 6 with a service of the assets 1. The at least one performance indicator 20 may be used 9 by the industrial control system 10 to control the industrial process 2, in particular to control the assets 1 of the industrial process 2.

[0038] Fig. 3 schematically illustrates the method 100 of Fig. 1 in more detail and with an additional step. After receiving 3 the asset state data of the assets 1 of the industrial process 3, the industrial control system 10 may generate 4 a plurality of performance indicators 20. In Fig. 3, two performance indicators 20 are generated 4. The plurality of performance indicators 20 may be based on the same asset state data of the assets 1, may share some of the asset state data of the assets 1 or may be based on different asset state data of the assets 1. The plurality of performance indicators 20 may be aggregated 5 to generate aggregated performance indicators 21.

[0039] Fig. 4 schematically illustrates the method of Fig. 1 in more detail. In Fig. 4, the assets 1 of the industrial process 2 may comprise a plurality of subunits 7, in particular multiple assets. The subunits 7 of the assets 1 may comprise a plurality of sub-subunits 8. The industrial process comprises assets at different levels of hierarchy, in Fig. 1 assets 1, subunits 7 and sub-subunits 8, that may all be assets 1 by themselves and that may comprise further levels of hierarchy. Exemplarily, the industrial process may comprise multiple industrial plants 1 that comprise production units 7 that comprise pieces of machinery 8. From each level of hierarchy, asset state data may be received 3 by the industrial control system 10. Performance indicators 20 may be generated 4 based upon asset state data received 3 from a plurality of levels of the hierarchy of the industrial process 2 or may bebased upon asset state data received 3 from one level of hierarchy of the industrial process 2.

Claims

CLAIMS1. A method for supervising an industrial process, the industrial process comprising a plurality of assets, the method comprising:- receiving, from at least one of the plurality of assets of the industrial process, asset state data representing at least one information on a state of the at least one of the plurality of assets;- generating at least one performance indicator based upon the asset state data; wherein the state is an automaton state from a discrete state space describing a service of at least one of the plurality of assets; and whereby the state is described by one and only one respective element of the discrete state space at any given point in time.

2. The method of claim 1, further comprising controlling the industrial process based upon the at least one performance indicator.

3. The method of any of the preceding claims, wherein the asset state data is received in a standardized format.

4. The method of any of the preceding claims, wherein receiving comprises a communication based on a standardized communication interface, in particular based on module type package, MTP.

5. The method of any of the preceding claims, wherein the asset state data is received at multiple points in time.

6. The method of claim 5, wherein the asset state data is received at regular points in time.

7. The method of any of the preceding claims, wherein the asset state data is received once a transition condition is met.

8. The method of any of the preceding claims, wherein the at least one performance indicator comprises at least one of an availability indicator, an utilization indicator or an effectiveness indicator.

9. The method of any of the preceding claims, wherein the at least one performance indicator is based upon the asset state data received at multiple points in time.

10. The method of any of the preceding claims, further comprising a visualization of the at least one performance indicator to a user.

11. The method of any of the preceding claims, wherein the plurality of assets comprises a plurality of state machines.

12. The method of claim 11, wherein the asset state data is generated by the plurality of state machines.

13. The method of any of the preceding claims, wherein the industrial process is a mining process.

14. The method of any of the preceding claims, wherein the at least one of the plurality of assets of the industrial process comprises a mobile asset.

15. An industrial control system configured for supervising an industrial process by the method of any of the preceding claims.

Images