Activation management for control program in controls

Abstract

The invention discloses a method for operating at least one field device of automation technology, by means of which communication and data exchange are enabled from a control unit, an engineering unit, and the field device through a communication network, the field device has at least one first functionality to provide measured variables in chemical, physical or biological processes and / or to control of industrial plants and at least one second functionality that is different from the first functionality, the method comprising: assigning a control program to the field device through the engineering unit, the control program is stored in the memory of the control unit, the second functionality of the field device can be activated by the control program with the assistance of a first activation code and / or a second activation code; verifying the capability of the second functionality of the field device; verifying the presence of the first activation code and the second activation code; verifying the validity of the first activation code and / or the second activation code; activating the second functionality for the field device based on the presence and the validity of the first activation code; activating the second functionality for the field device for a limited time based on the presence and / or the validity of the second activation code; blocking the second functionality for the field device if the first activation code is not present or not valid and the limited time is expired, until the first activation code is present and valid.

Description

[0001] Activation management for control program in controls

[0002] Technical Field

[0003] The present invention relates to a method for operating one or more field devices of automation technology, the one or more field devices are capable of at least one first functionality and at least one second functionality. The present invention relates also to a system for implementing the method, and a control program to carry out the method.

[0004] Background Art

[0005] Automation is the use of largely automatic equipment in a system of manufacturing or other production process. This typically includes the use of programmable logic controllers (PLCs), sensors, robots, and motors among many other things depending on the automated process. There is usually very little human intervention. Input devices, such as sensors and switches, will work with a controller or PLC to activate output devices like motors or other machinery. The PLC will advance as it was programmed.

[0006] A programmable logic controller or a PLC is an industrial controller, which is simply a special computer that is programmed to control certain processes in industries like petroleum, steel, or automotive. Every PLC is composed of three main parts: input, CPU, and output. Suppose that we have an electrical motor and a push button. We want the motor to turn on when the button is pressed. When the button is pressed again, we want the motor to turn off. To do this, we must first write a program for this operation on a computer and then download it to the CPU. Then we connect the switch to the input and the motor to the output. Now if we press the button, an electrical signal will be sent to the PLC. The PLC input will deliver this signal to the CPU but first must present it in a format that the CPU can process, because the CPU is a computer system and cannot process the raw electrical signal. The CPU will process the data received and send the result to the output. The output turns the data to a raw electrical signal again and applies that to the motor and turns it on. Now if we press the button again, the process repeats, and the motor will turn off. In an automated process, that output will typically act as an input to the PLC and combined with other input devices or programming, to keep the process running. With this programming, it can act like a chain reaction with one output device starting before the next is allowed to run.

[0007] A distribution control system or a DCS is an industrial control system like a PLC, however the DCS contains multiple autonomous controllers that are distributed throughout a system, which are also used for automating processes. In industrial automation process, especially for automation of chemical processes or procedures for producing a product from a raw or starting material using chemical, physical, or biological processes and / or for control of industrial plants, measuring devices installed near to the process, so-called measuring field devices and / or actuators installed near to the process, such as control elements or valves, are applied. These devices installed near to the process are also referred to as field devices. Field devices embodied as sensors can monitor, for example, process measurement variables, such as pressure, temperature, flow, fill level or measured variables of liquid or gas analysis, such as pH- value, conductivity, concentrations of certain ions, chemical compounds and / or concentrations or partial pressures of gases.

[0008] Process sensors fulfill their primary purpose of process automation by providing characteristic measured variables such as flow, level, pressure, temperature, conductivity, or pH value. In addition, modern sensors also offer comprehensive features for monitoring their own functional status. During their own digital transformation, field measuring devices have been equipped with extensive diagnostic capabilities, in-situ device verification as well as monitoring capabilities. For example, field measuring devices equipped with these optional additional capability or functionality modules can provide measured variables together with the associated key performance indicators (KPIs), which can be used for further evaluation.

[0009] Many such field devices are produced and sold by Endress+Hauser.

[0010] Field device functionalities are enabled specifically by the control programs in the PLC / DCS and are thus accessible to the plant operator. These functionalities are often to be used commercially via device-specific licenses (pay per use), especially those optional additional functionalities.

[0011] Technical Problem

[0012] The invention is based on the following problem, that in case of failure of field devices or PLC / DCS components, certain functionalities are no longer available after the replacement of the field devices or PLC / DCS components, and must be enabled again with considerable effort, especially those optional additional functionalities to perform, for example, diagnostic, verification, and monitoring functions.

[0013] Solution to Problem

[0014] The object of the present invention is to provide a simple, user-guided procedure that ensures that after a device failure or failure of a PLC / DCS component, an optional additional functionality is reactivated in the shortest possible time and can thus be used again immediately. Furthermore, the activation can be performed without the assistance of a specialist. The object is achieved by the method specified in independent claim 1 , the system described in claim 13 for carrying out the method, and the control program comprising instructions which, when the control program is executed by the system of claim 13, to carry out the verifying, activating, and blocking steps of the method of claim 1.

[0015] Method-wise the object is solved by means of which communication and data exchange are enabled from a control unit, an engineering unit, and at least one field device through a communication network, the field device has at least one first functionality to provide measured variables in chemical, physical or biological processes and / or to control of industrial plants and at least one second functionality that is different from the first functionality, the method comprising: assigning a control program to the field device through the engineering unit, the control program is stored in the memory of the control unit, the second functionality of the field device can be activated by the control program with the assistance of a first activation code and / or a second activation code, verifying the capability of the second functionality of the field device, verifying the presence of the first activation code and the second activation code, verifying the validity of the first activation code and / or the second activation code, activating the second functionality for the field device based on the presence and the validity of the first activation code, activating the second functionality for the field device for a limited time based on the presence and / or the validity of the second activation code, and blocking the second functionality for the field device if the first activation code is not present or not valid and the limited time is expired, until the first activation code is present and valid.

[0016] Advantageously, the at least one second functionality comprises at least one of: a diagnostic function, a verification function, a monitoring function, a custody transfer function, and a data storage function.

[0017] In one embodiment, the control program comprises a function block.

[0018] In one embodiment, the control unit comprises an industrial controller for process control, comprising at least one of: a programmable controller (PLC) and a distributed control system (DCS).

[0019] In one embodiment, the engineering unit is a computer comprising an engineering framework for programming, commissioning, and / or maintaining automation systems, the engineering unit enables users to work with the control unit and the one or more field devices through the communication network.

[0020] In one embodiment, the first activation code is device-specific and / or is bounded to the serial number of the field device. In one embodiment, the second activation code is accessible to the control program.

[0021] In one embodiment, the method further comprising requesting entry of the first activation code and / or the second activation code.

[0022] In one embodiment, the method further comprising enabling the first activation code to be ordered from a backend system.

[0023] In one embodiment, the method further comprising enabling entry of the first activation code and / or the second activation code at the engineering unit and / or at a plant operator’s working station.

[0024] In one embodiment, the verifying, activating, blocking, requesting, and enabling steps are accomplished by the control program and / or by a different program stored in the memory of the field device.

[0025] In one embodiment, the method further comprising entering the first activation code and / or the second activation code at the engineering unit and / or at the plant operator’s working station to activate the second functionality.

[0026] This is explained in more detail with the accompanying drawings in which:

[0027] Fig. 1 illustrates an example system;

[0028] Fig. 2 illustrates an example method embodiment for activating a second functionality;

[0029] Fig. 3 illustrates an example workflow for commissioning a control program in general and / or after a PLC / DCS component replacement; and

[0030] Fig. 4 illustrates an example workflow for commissioning a control program after a field device replacement.

[0031] Referring to Fig. 1 , a system comprising at least one field device 11 , a control unit 12, an engineering unit 13, and a communication network 14, where the communication network 14 links the control unit 12 and the engineering unit 13 to the field device 11 and enables digital communication and data exchange.

[0032] The field device 11 has a first functionality of measuring variables such as flow, level, pressure, temperature, conductivity, or pH value in the industrial processes. Beyond this, the field device 11 has a second functionality that offers a wide variety of diagnostic parameters (diagnostic function), which can be condensed into user-friendly information in the form of use case relevant indices, e.g., indicating the presence of corrosion, abrasion, or build-up. Consequently, continuous information about the status and integrity of the device as well as insights regarding the fluid properties and the process conditions can be provided. The second functionality also offers useful information regarding the functionality of the device and its expected performance, or even the larger asset.

[0033] The user typically obtains such information either as a diagnostic message, via the verification function or by monitoring measured variables (monitoring function), diagnostic parameters, or indices.

[0034] For example, field devices with such a second functionality include a variety of devices featuring "Heartbeat Technology" from Endress+Hauser, such as flow meters, level measuring devices, pressure transmitters, thermometers, liquid analysis measuring devices, and more.

[0035] The control unit 12 is an industrial computer or a computerized control system used for industrial process control. It could be an industrial controller such as a programmable logic controller (PLC) or a distributed control system (DCS). The control unit 12 may further comprise a human-machine interface (HMI) allowing the control unit 12 to interact with people for the purpose of configuration, alarm reporting, or everyday control.

[0036] The engineering unit 13 comprises an engineering framework for programming, commissioning, and / or maintaining automation systems. It enables the user to work with the control unit 12 and the field device 11 through the communication network 14, e.g., assigning PLC programs to field devices. The engineering unit 13 could be a computer.

[0037] The communication network 14 is an industrial digital communication network. In modern industrial plants, field devices are usually connected to higher-level units (such as PLCs / DCSs) via industrial digital communication networks or systems (Profibus®, Foundation® Fieldbus, HART®, etc.). It enables communication and data exchange between various field devices and systems.

[0038] Fig. 2 illustrates an example method embodiment for activating a second functionality by the control program 25. The field device 21 has a first functionality of measuring the level of a process medium in a tank and a second functionality for diagnostics, verification, and monitoring of the field device 21 throughout the useful lifetime of the measuring device. The control program 25 stored in the memory of a control unit 22 can activate or block the second functionality for the field device 21.

[0039] In one embodiment, the control program 25 is a function block, e.g., supported by standard IEC 61131-3: 2013. A function block is a PLC program created to control machine operation.

[0040] The user first assigns the control program 25 to the field device 21 through an engineering unit 23. The assignment is made using a tag (see Tag 2 in Fig. 2). A tag is created in the PLC program to represent a field device. A tag number is a code combination of letters and numbers that contains information for the component being represented. Through the tag, the control program 25 can have access to the device documentation of the field device 21 . The control program 25 checks if the field device 21 supports the second functionality. If the field device 21 is not capable of the second functionality, the second functionality is deactivated by the control program 25.

[0041] In one embodiment, the control program 25 verifies the presence and validity of a first activation code. If the first activation code is present and valid, the second functionality is activated by the control program 25 permanently. Preferably, the control program 25 verifies the presence of a second activation code. If the first activation code is not present for the control program 25, or the first activation code is present but not valid, the second functionality is activated for a limited time, e.g., 30 days, with assistance of the second activation code. The control program 25 is directly accessible to the second activation code, for example, it is stored in the device documentation of the field device 21 . After assigning the control program 25 to the field device 21 through the tag, the control program 25 has the access to the device documentation.

[0042] In one embodiment, the control program 25 verifies the validity of the second activation code as well. In this case, the second activation code is not directly accessible to the control program 25. The user must enter the second activation code in the same manner as he enters the first activation code. If the first activation code is not present or not valid, and second activation code is present and valid, the second functionality is activated for a limited time.

[0043] Preferably, the control program 25 blocks the second functionality for the field device 21 , when the limited time expires. The user will have to enter a valid first activation code to activate the second functionality.

[0044] The first activation code is a device-specific code and bounded to the serial number (see SeNo 2 in Fig. 2) of the field device 21. In this example, the first activation code is created by the manufacturer’s central license manager at a backend system 26.

[0045] The control program 25 requests entry of the first activation code at the engineering unit 23 and / or at a plant operator’s working station (not shown in Fig. 2, see 37 in Fig. 3, see 47 in Fig. 4). The user can enter the first activation code at the engineering unit 23 or at the working station. The plant operator’s working station could be a control room or operations room used for the purpose of production control, which is a central space where a large physical facility or physically dispersed service can be monitored and controlled.

[0046] In one embodiment, the entry of the first activation code is requested immediately following the assignment of the control program 25 to the field device 21 . The user can enter the first activation code or the second activation code immediately at the engineering unit 23 or later at the plant operator’s working station. If the first activation code is not entered immediately following the assignment, the control program 25 is activated only temporarily in case of the control program 25 is directly accessible to the second activation code. In one embodiment, the verifying, activating, blocking, requesting, and enabling steps are accomplished by the control program 25 and / or by a different program stored in the memory of the field device.

[0047] Fig. 3 illustrates an example workflow for commissioning a control program 35 in general and / or after a PLC / DCS component replacement. In this example, the steps of commissioning are taken place in an engineering unit 33, e.g., a computer (steps S301-S305), in a control program 35, e.g., a function block (conditional checks C301-C302, step S306), in a plant operator’s working station 37, e.g., a control room (conditional check C303, steps S307-S308 and S311-S313), and in a backend system 36, e.g., a server of Endress+Hauser (steps S309-S310).

[0048] At the engineering unit 33, the user can start by downloading S301 a function block library from a Endress+Hauser website. The user can then install S302 the library and assign S303 the function block to a dedicated field device. If a first activation code is available to the user, he can enter S304 the first activation code immediately into the engineering unit 33, and then download S305 the function block to a control unit, e.g., a PLC (not shown in Fig. 3). However, if the first activation code is not available to the user, the step S304 will be skipped.

[0049] The function block then checks C301 if the field device is capable of a second functionality, e.g., a diagnostic function. If the field device is not capable of the diagnostic function, this diagnostic function is deactivated, and a plant operator is informed by means of such as displaying S313 “Field device does not support diagnostic function”, at his working station 37. However, if the field device is capable of the diagnostic function, the function block checks C302 if the first activation code has been already entered and if it is valid. If the first activation code has been already entered (e.g., through step S304) and is valid, the diagnostic function is activated, and the commissioning is complete. If the first activation code is not present or it is present but not valid for the function block, the diagnostic function of the field device is activated by the function block and runs temporarily S306. In this example, the function block is directly accessible to a second activation code.

[0050] At the operator’s working station 37, a notice is displayed S307 such as “Enter activation code within xx days” after the diagnostic function is activated temporarily S306. The user then checks C303 if the first activation code is available. If the first activation code is available to the user, he can enter S312 the first activation code at the operator’s working station 37. If the first activation code is not available to the user, the function block further enables the first activation code to be ordered S308 from the backend system 36, e.g., the server of Endress+Hauser. If the first activation code has not been entered “within xx days”, the diagnostic function of the field device will be blocked by the function block, until the first activation code is present and valid. A license manager can create S309 the first activation code for the field device at the server and then provides S310 the user the first activation code. The user can enter S311 the first activation code at the operator’s working station 37, and the commissioning is complete.

[0051] Fig. 4 illustrates an example workflow for commissioning a control program 45 after a field device replacement. In this example, the steps of commissioning are taken place on-site at the process plant 48 (step S414), in a control program 45, e.g., a function block (conditional checks C401 , step S406), in a plant operator’s working station 47, e.g., a control room (conditional check C403, steps S407-S408 and S411-S413), and in a backend system 46, e.g., a server of Endress+Hauser (steps S409-S410).

[0052] After replacing S414 a field device, the plant operator starts S415 a verification at his working station 47, which executes the function block.

[0053] The function block checks if the field device is capable of a second functionality C401 supported by “Heartbeat Technology” from Endress+Hauser. If the field device is not capable of the second functionality, the second functionality is deactivated, and the plant operator is informed by means of such as displaying S413 “Field device does not support Heartbeat Technology”. However, if the field device is capable of the second functionality, the second functionality is activated and runs temporarily S406. In this example, the function block is directly accessible to a second activation code.

[0054] At the operator’s working station 47, a notice is displayed S407 such as “Enter activation code within xx days” after the second functionality is activated temporarily S406. The user then checks C403 if a first activation code is available. If the first activation code is available to the user, he can enter S412 the first activation code at the operator’s working station 47. If the first activation code is not available, the function block enables the first activation code to be ordered S408 from the backend system 46, e.g., the server of Endress+Hauser.

[0055] A license manager can create S409 the first activation code for the field device at the server and then provides S410 the user the first activation code. The user can enter S411 the first activation code at the operator’s working station 47, and the commissioning is complete. List of reference signs

[0056] 11 Field device

[0057] 12 Control unit

[0058] 13 Engineering unit

[0059] 14 Communication network

[0060] 21 Field device

[0061] 22 Control unit

[0062] 23 Engineering unit

[0063] 25 Control program

[0064] 26 Backend system

[0065] 33 Engineering unit

[0066] 35 Control program

[0067] 36 Backend system

[0068] 37 Plant operator’s working station

[0069] 45 Control program

[0070] 46 Backend system

[0071] 47 Plant operator’s working station

[0072] 48 Process plant

[0073] C301 Check if the field device is capable of a second functionality

[0074] C302 Check if the first activation code has been already entered and if it is valid

[0075] C303 Check if the first activation code is available

[0076] C401 Check if the field device is capable of a second functionality

[0077] C403 Check if the first activation code is available

[0078] 5301 Download a function block library

[0079] 5302 Install the library

[0080] 5303 Assign function block to dedicated field device

[0081] 5304 Enter first activation code

[0082] 5305 Download function block to a control unit

[0083] 5306 Run function block temporarily

[0084] 5307 Display “Enter first activation code within xx days”

[0085] 5308 Oder option to use function block

[0086] 5309 Create first activation code for field device

[0087] 5310 Provide customer first activation code

[0088] 5311 Enter first activation code

[0089] 5312 Enter first activation code

[0090] 5313 Display “Field device does not support second functionality”

[0091] S406 Run function block temporarily 5407 Display “Enter first activation code within xx days”

[0092] 5408 Oder option to use function block

[0093] 5409 Create first activation code for field device

[0094] S410 Provide customer first activation code

[0095] S411 Enter first activation code

[0096] S412 Enter first activation code

[0097] 5413 Display “Field device does not support second functionality”

[0098] 5414 Replace field device on-site

[0099] 5415 Start verification

Claims

Claims1 . A method for operating at least one field device (11 , 21) of automation technology, by means of which communication and data exchange are enabled from a control unit (12, 22), an engineering unit (13, 23, 33), and the field device (11 , 21) through a communication network (14), the field device (11 , 21) has at least one first functionality to provide measured variables in chemical, physical or biological processes and / or to control of industrial plants and at least one second functionality that is different from the first functionality, the method comprising:- assigning a control program (25, 35, 45) to the field device (11 , 21) through the engineering unit (13, 23, 33), the control program (25, 35, 45) is stored in the memory of the control unit (12, 22), the second functionality of the field device (11 , 21) can be activated by the control program (25, 35, 45) with the assistance of a first activation code and / or a second activation code,- verifying the capability of the second functionality of the field device (11 , 21),- verifying the presence of the first activation code and the second activation code,- verifying the validity of the first activation code and / or the second activation code,- activating the second functionality for the field device (11 , 21) based on the presence and the validity of the first activation code,- activating the second functionality for the field device (11 , 21) for a limited time based on the presence and / or the validity of the second activation code, and- blocking the second functionality for the field device if the first activation code is not present or not valid and the limited time is expired, until the first activation code is present and valid.

2. The method according to claim 1 , the at least one second functionality comprises at least one of: a diagnostic function, a verification function, a monitoring function, a custody transfer function, and a data storage function.

3. The method according to at least one of claims 1 to 2, the control program (25, 35, 45) comprises a function block.

4. The method according to at least one of claims 1 to 3, the control unit (12, 22) comprises an industrial controller for process control, comprising at least one of: a programmable controller (PLC) and a distributed control system (DCS).

5. The method according to at least one of claims 1 to 4, the engineering unit (13, 23, 33) is a computer comprising an engineering framework for programming, commissioning, and / or maintaining automation systems, the engineering unit (13, 23, 33) enables users to work with the control unit (12, 22) and the field device (11 , 21) through the communication network (14).

6. The method according to at least one of claims 1 to 5, the first activation code is devicespecific and / or is bounded to the serial number of the field device (11 , 21).

7. The method according to at least one of claims 1 to 6, the second activation code is accessible to the control program (25, 35, 45).

8. The method according to at least one of claims 1 to 7, further comprising requesting entry of the first activation code and / or the second activation code.

9. The method according to at least one of claims 1 to 8, further comprising enabling the first activation code to be ordered from a backend system (26, 36, 46).

10. The method according to at least one of claims 1 to 9, further comprising enabling entry of the first activation code and / or the second activation code at the engineering unit (13, 23, 33) and / or at a plant operator’s working station (37, 47).11 . The method according to at least one of claims 1 to 10, the verifying, activating, blocking, requesting, and enabling steps are accomplished by the control program (25, 35, 45) and / or by a different program stored in the memory of the field device.

12. The method according to at least one of claims 1 to 11 , further comprising entering the first activation code and / or the second activation code at the engineering unit (13, 23, 33) and / or at the plant operator’s working station (37, 47) to activate the second functionality.

13. A system for implementing the method according to at least one of claims 1 to 12, comprising: at least one field device (11 , 21) of automation technology, the field device (11 , 21) has at least one first functionality to provide measured variables in chemical, physical or biological processes and / or to control of industrial plants and at least one second functionality that is different from the first functionality, a control unit (12, 22) configured for controlling the second functionality of the field device (11 , 21) through a control program (25, 35, 45) stored in the memory of the control unit (12, 22), the second functionality of the field device (11 , 21) can be activated by the control program (25, 35, 45) with assistance of a first activation code and / or a second activation code, an engineering unit (13, 23, 33) configured for assigning the control program (25, 35, 45) to the field device (11 , 21), a communication network (14) configured for enabling communication and data exchange from the field device (11 , 21), the control unit (12, 22), and the engineering unit (13, 23, 33),the system is configured for, when the control program (25, 35, 45) is executed, causing the control program (25, 35, 45) to carry out:- verifying the capability of the second functionality of the field device (11 , 21),- verifying the presence of the first activation code and the second activation code, - verifying the validity of the first activation code and / or the second activation code,- activating the second functionality for the field device (11 , 21) based on the presence and the validity of the first activation code,- activating the second functionality for the field device (11 , 21) for a limited time based on the presence and / or the validity of the second activation codes, and - blocking the second functionality for the field device if the first activation code is not present or not valid and the limited time is expired, until the first activation code is present and valid.

14. A control program (25, 35, 45) comprising instructions which, when the control program is executed by the system of claim 13, to carry out the verifying, activating, and blocking steps of the method of claim 1 .

Images