Method and system for commissioning, operating and / or maintaining a measurement point in an automation technology system
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- ENDRESSHAUSER GRP SERVICES AG
- Filing Date
- 2024-07-02
- Publication Date
- 2026-07-01
Smart Images
Figure EP2024068537_27022025_PF_FP_ABST
Abstract
Description
[0001] Method and system for commissioning, operating and / or maintaining a measuring point in an automation system
[0002] The invention relates to a method for commissioning, operating, and / or maintaining a measuring point in an automation system. Furthermore, the invention relates to a system configured to implement the method according to the invention.
[0003] Field devices used in industrial plants are already known from the state of the art. Field devices are widely used in process automation technology, as well as in manufacturing automation technology. Field devices essentially refer to all devices used close to the process and that provide or process-relevant information. Field devices are used to record and / or influence process variables. Measuring devices or sensors are used to record process variables. These are used, for example, for pressure and temperature measurement, conductivity measurement, flow measurement, pH measurement, level measurement, etc., and record the corresponding process variables such as pressure, temperature, conductivity, pH value, level, flow, etc. Actuators are used to influence process variables.These include, for example, pumps or valves that can influence the flow of a fluid in a pipe or the fill level in a container. In addition to the previously mentioned measuring devices and actuators, field devices also include remote I / Os, wireless adapters, and generally devices located at the field level.
[0004] A large number of such field devices are produced and distributed by the Endress+Hauser Group.
[0005] In modern industrial plants, field devices are usually connected to higher-level units via communication networks such as fieldbuses (Profibus®, Foundation® Fieldbus, HART®, etc.). These higher-level units are usually control systems (DCS) or control units such as a PLC (programmable logic controller). The higher-level units are used, among other things, for process control, process visualization, process monitoring and for commissioning the field devices. The measured values recorded by the field devices, particularly sensors, are transmitted via the respective bus system to one (or possibly several) higher-level units. In addition, data transmission from the higher-level unit to the field devices via the bus system is also required, particularly for the configuration and parameterization of field devices and for controlling actuators.Mobile control units can also be used to operate field devices that have implemented an FDT framework application. For example, there are control units that are connected to the fieldbus network. However, the control unit can also communicate with the field devices via a wireless communication connection, particularly based on a Bluetooth standard. The applicant produces and distributes devices that, as so-called Bluetooth gateways, allow the control units to be connected to the field devices. The field device is connected to a Bluetooth gateway via a wired connection, particularly using the HART or CDI communication standards. Alternatively, the field devices themselves have their own Bluetooth interfaces.
[0006] If a mobile device, such as a smartphone or tablet, is used as an operating unit for wireless communication with the field devices, application programs, so-called apps, are available which make the operating functions for the field device available to the mobile device.
[0007] Tools are now available to assist potential customers in planning and ordering field devices from manufacturers. The applicant, for example, provides such applications online, such as the "CEP" (short for "Central Engineering Platform") application, which designs or projects a field device based on imported process and environmental parameters of the future application and performs size calculations (e.g., the nominal diameter or flange diameter, etc.). After the planning phase is completed, the field device is ordered and installed by the customer in the system. During production, field devices are typically calibrated within standard ranges rather than within process- and customer-specific values. A cross-manufacturer data chain cannot be created because there is no way to link the various data sources.Furthermore, it's unclear which measurement system (SI or imperial) customers use. For example, a device built in Switzerland is always calibrated in SI units, even if it is subsequently shipped to the USA, for example. Furthermore, the production site currently has no access to the design data.
[0008] Experience shows that when a field device needs to be replaced at the end of its life cycle, the customer typically orders an identical replacement (based on the order code) or directly orders a one-to-one replacement device. Often, the process parameters are not considered again, relying on having received a suitable recommendation when ordering the original field device. However, a better-fitting or less expensive field device may now be available. The process parameters may also have changed in the meantime, meaning the original selection is no longer the optimal one for today.
[0009] With this approach, the customer also wants to avoid a complex reconfiguration, as the old field device parameters can be adopted directly or the original (or since changed, currently applicable) process parameters are difficult to determine. One reason for this is that unlinked databases are used for various processes (ordering, calibration, maintenance, etc.). Furthermore, the original design of the field device is often no longer available or cannot be found. A successor device is usually redesigned manually according to process parameters that are ideally still valid. However, the data or information required for this is typically imported manually from older documents, as there is no digitization in this regard, which can lead to errors.
[0010] Obtaining a complete history of the measuring point and previously used (various) field devices, as well as previous calculation bases, is very difficult, if not impossible, at a later date. Current concepts of digital images (also called "digital twins") are practically always linked to the serial numbers of the corresponding field devices. DE 10 2012 101 461 A1, for example, describes a process in which data about a field device is recorded over the course of its life cycle and stored under a unique identifier. A major disadvantage, however, is that a field device must already exist for this to happen. In the project planning or engineering phase, however, no physical device with a serial number exists yet – and one may never exist, for example, if it is not subsequently ordered.
[0011] Based on this problem, the invention is based on the object of presenting a concept that allows comprehensive data acquisition of a field device.
[0012] The object is achieved by a method according to claim 1 and by a system according to claim 10.
[0013] With regard to the procedure, it is intended that the procedure serves to commission, operate and / or maintain a measuring point in an automation system and comprises the following procedural steps:
[0014] Planning one or more field devices for use in the measuring point, wherein unique identification information is generated for the planning for each field device, wherein each of the unique identification information is stored in a database with a measuring point identification of the measuring point, wherein requirement information containing information on the application of the measuring point is entered for the planning, and wherein the requirement information is stored in the database linked to the unique identification information;
[0015] Proposals of at least one concrete field device for one or more of the projected field devices based on requirement information, wherein each of the proposed concrete field devices contains a field device type, and in particular a configuration proposal, wherein the proposed concrete field devices are stored in the database linked to the corresponding unique identification information;
[0016] Ordering one or more field devices from the set of proposed field devices, whereby a serial number is created for each of the ordered field devices during the ordering process, whereby the serial numbers of the ordered field devices are stored in the database linked to the corresponding unique identification information; and
[0017] Installation and commissioning of the ordered field device(s) as an existing field device(s) in the measuring point.
[0018] According to the invention, each field device potentially usable in the future measuring point is assigned unique identification information directly during the planning phase and linked to the measuring point's identification. This unique identification information can be a numeric or alphanumeric character string of a predefined length. This identification information is not the field device's serial number. If one of the field devices potentially usable in the future measuring point is actually ordered after the planning phase, the unique identification information is linked to the field device's serial number. This allows the complete history to be captured, even if the field device is replaced at a later date.
[0019] The data that led to the specific selection of a field device (information on the measuring point application, suggested field device type, configuration suggestion, if applicable, etc.) are also linked to the unique identification information. This allows a field device manufacturer to verify the exact input parameters for the device suggestion or device selection and why exactly this field device was recommended (e.g., to fulfill verification obligations, etc.).
[0020] The information on the application of the measuring point includes, for example, data regarding the process engineering process that is to be monitored and / or controlled by the measuring point and / or environmental data for the measuring point, e.g. temperature data, information on air humidity, etc.
[0021] Field devices which are mentioned in connection with the method according to the invention have already been listed as examples in the introductory part of the description.
[0022] According to one embodiment of the method, it is provided that the method additionally comprises the following method step:
[0023] Calibration and / or parameterization of the existing field device(s) prior to installation and commissioning in the measuring point or during installation and commissioning in the measuring point, whereby the calibration and / or parameter data used for calibration and / or parameterization are stored in the database linked to the corresponding unique identification information.
[0024] This allows access to data relevant for commissioning, i.e. calibration and / or parameter data, at a later point in time, for example during a field device exchange, which can be used, for example, for commissioning a replacement field device of the same device type.
[0025] Furthermore, it is advantageously provided that, over the course of the measuring point's life cycle, data regarding changes and / or maintenance for each of the existing field devices is stored in the database, linked to the corresponding unique identification information. Thus, the complete history of a field device—from the entry of the required data during the configuration phase, through device selection, to change and maintenance data—can be stored as the measuring point's history under the unique identification information.
[0026] Examples of such data may include one or more of the following:
[0027] Data sheets from manufacturers,
[0028] Records of delivery routes,
[0029] Lifecycle management data,
[0030] Calibration data, setup / configuration / maintenance data,
[0031] Information about the phasing out of an existing field device or a field device type, graphic information, design data, in particular CAD data;
[0032] Maintenance plans, existing and future maintenance costs,
[0033] Information about the current monetary value, a digital fingerprint, digital records of the state of the field device, information about the geographical location.
[0034] This is a non-exhaustive list. Those skilled in the art will be aware that there are other data types that may be collected during the process and linked and stored with the unique identification information.
[0035] One embodiment of the method provides that the data linked to the unique identification information in the database is made available to a user automatically or upon request. The user can access the database, in particular, via the internet using a device (laptop, smartphone, tablet, etc.).
[0036] According to one embodiment of the method, if a replacement device is required for one of the existing field devices, at least one specific field device is proposed as a replacement field device based on the requirement information linked to the unique identification information of the field device to be replaced. When exchanging or replacing a field device, the set of original requirement information is thus considered again. This allows a current field device to be selected that may be even more suitable for the application than the originally used field device.
[0037] An advantageous embodiment of the method provides that at regular intervals or when required, a check is carried out for each of the field devices to determine whether the application information contained in the requirement information still corresponds to the current application information, wherein, in the event that a check is carried out for one or more of the requirement field devices to determine that the application information contained in the requirement information does not correspond to the current application information, at least one specific field device is proposed as a replacement field device for each affected existing field device based on the current application information.If, for example, process parameters change over time (due to a pressure drop in an oil well), these are entered by the plant operator and compared with the originally entered inventory information. The plant operator then checks the design of the currently used device. If the deviations are too large, a more suitable field device can be automatically suggested for replacement.
[0038] Alternatively, it can be suggested that the existing field device be recalibrated if the application information contained in the demand information does not correspond too closely to the current application information. After recalibration, the new calibration data is stored linked to the unique identification information, and the demand information is updated in the database.
[0039] According to an advantageous detailing of the method, it is proposed that the replacement field device is calibrated and / or parameterized using the calibration and / or parameter data linked to the unique identification information of the field device to be replaced.
[0040] According to an advantageous embodiment of the method, the data linked to the unique identification information is linked to respective digital images of the corresponding existing field devices. A digital image is a virtual representation of a field device that has the same properties as the real field device. For example, the digital image is assigned the same configurations and parameter settings as the real field device. The current device status can also be obtained via the virtual image. Since such a digital image is linked to the unique identification information of a field device and not to its serial number, such a digital image also exists for field devices that do not progress beyond the project planning phase (i.e., for every field device that could exist at some point according to the specifications in the project planning phase).
[0041] With regard to the system, it is provided that the system is designed to carry out the method according to the invention and comprises one or more existing field devices and a database.
[0042] One system configuration provides for a cloud-based database. Alternatively, the database can be a distributed database system composed of individual databases. In both variants, the user can connect to and access the database via the internet using a device (laptop, smartphone, tablet, etc.).
[0043] The database may also be linked to one or more applications (e.g., running on the same server) that allow the display, retrieval and / or processing of the data contained in the database.
[0044] The invention is explained in more detail with reference to the following figures.
[0045] Fig. 1 : a schematic overview of a method known from the prior art; and
[0046] Fig. 2: A schematic overview of an embodiment of the method according to the invention. Fig. 1 shows the life cycle of an existing field device FG' using methods known from the prior art and typically used in today's systems. Several milestones, or points in time t0' to t9', in the life of an existing field device FG' are depicted on a timeline t.
[0047] First, a planning phase PJ' is carried out. In this planning phase PJ', the measuring point is planned, as well as one or more field devices to be used for this measuring point. At time t0', the customer selects one or more field devices. These can be identified in advance using a tool, for example, by entering requirement information containing, for example, information on the application of the measuring point. The tool then suggests several types of field devices based on the requirement information. This is where the first problem arises, indicated by a lightning symbol: This requirement information is not recorded and is lost. It is later unclear which field device types were suggested to the user and on what basis.
[0048] At a time t1', the customer orders one or more of the selected field devices. This information is stored in a database DB'. The dashed arrows indicate an interaction with the database DB', or a data transfer from the database DB' and / or to the database DB'.
[0049] The planning phase PJ' ends with the start of the production phase PD', in which the field device is manufactured. At time t2', a serial number SN' is created for the field device and stored in the database DB'. The problem here is that this serial number SN' will serve as the starting point or link for all further information regarding the field device. Information that already existed at an earlier point in time will be lost.
[0050] The planning phase ends at time t3', which initiates the calibration phase KL'. The field device is calibrated using standard data, and the results are stored in the database DB'. The problem with calibration is that only a standard calibration is performed, without considering the customer-specific use of the field device, since the required information is unknown. For example, it is not known whether the customer uses the metric or imperial system of units, or within which value limits the field device will later operate. The calibration phase ends at time t4' with the generation of a standard calibration certificate (based on the standard data, e.g., based on metric units).
[0051] After calibration, the field device is shipped in the delivery phase L1' and handed over to the customer at time t5'. After installation, the field device becomes an existing field device FG', which is parameterized at time t6' and used from time t7'. Data generated here is not stored in the database DB', which stores the field device's previous information. Now the operating phase of the existing field device FG' begins. Here, too, the data generated here is typically not transferred to the database DB'.
[0052] At time t8', the field device manufacturer performs a so-called phase-out of the field device family. This means that the field device family is replaced with a newer version or a new field device type. A one-to-one replacement for the existing field device FG' no longer exists from this point onward.
[0053] At time t9', an irreparable defect occurs in the existing field device FG', which requires its replacement. Since the demand information can no longer be found, the customer must manually compile it and start again from the beginning, starting at time t0'.
[0054] These disadvantages are overcome by the method according to the invention, which is to be illustrated by the embodiment shown in Fig. 2.
[0055] The core of the process is that at the beginning of the project planning phase PJ, at time tO, a unique identification information ID is generated for each of the projected field devices and stored in the database DB. The database DB is, in particular, a cloud-based database. "Cloud-based" means that the database DB is hosted on a server that is accessible via the Internet. In addition, one or more applications can be assigned to the database, which are executed from the server. The applications allow the viewing and / or processing of the data in the database DB. Alternatively, the database DB can be a distributed database system composed of individual (sub)databases.
[0056] Also in connection with Fig. 2, the dashed arrows mean an interaction with the database DB, or a data transmission from the database DB and / or to the database DB.
[0057] The unique identification information ID is used as a key or reference point for saving all further actions relating to this configured field device in the database DB. This occurs regardless of whether the field device is actually physically built at the end. The identification information ID is used to save field device-related data throughout the entire life cycle of the field device. The requirement information entered at time tO is stored in the database DB linked to the identification information ID. Specifically, all information that contributed to the product proposal and the specific product selection is saved. For example, to create the product proposal, various process parameters are already entered into a web tool as information on the application of the measuring point, e.g.Information regarding the medium to be measured, the expected flow value in a flow measurement application, etc.
[0058] The web tool creates one or more suggestions for each of the configured field devices. These suggestions are also stored in the database DB, linked to the identification information (ID).
[0059] At time t1, the user orders one or more of the suggested field devices. This selection is also stored in the database DB.
[0060] In the production phase PD, the selected field device is produced. At time t2, a serial number SN is generated, which is stored in the database DB linked to the identification information ID of the corresponding field device. Thus, in contrast to prior art practices, the serial number SN is only one of many attributes that are also linked to the unique ID.
[0061] In the calibration phase KL, the field device is calibrated at time t3. The produced field device is calibrated based on the demand information stored in the database. This eliminates standard calibration, as process parameters can be accessed directly via the demand information. The calibration phase KL ends at time t4 with the generation of the calibration certificate, which refers, among other things, to application-specific data, such as a unit system.
[0062] After calibration, the field device is shipped in the delivery phase LI and handed over to the customer at time t5.
[0063] After installation, the field device is an existing field device (FG), which is parameterized at time t6. However, parameterization can be brought forward, as the field device can already be parameterized during production based on the requirements information. The existing field device (FG) can therefore ideally be used immediately (time t7).
[0064] The operating phase of the existing field device FG now begins. It can be provided that data from the existing field device FG generated during this operating phase is transferred to the database DB and stored linked to the identification information ID. In particular, it is provided that a digital image DT of the existing field device FG is available, which is kept up-to-date with the data generated during the operating phase. Data from other data sources DQ, e.g., maintenance data from a maintenance server, can also be transferred to the database DB and linked to the identification information ID.
[0065] At time t8, the field device manufacturer performs a phase-out of the field device family. This means that the field device family is replaced with a newer version or a new field device type. A one-to-one replacement for the existing field device FG no longer exists from this point onward.
[0066] At time t9, an irreparable defect occurs in the existing field device FG', which requires its replacement. Based on the demand information available in the database, a suitable replacement for the failed existing device with a different device type can be suggested. It can also be assumed that the demand information has been adjusted over time, and a now even more suitable field device is suggested as a replacement. The (adjusted) demand information can be used directly for device configuration and calibration.
[0067] The device is also delivered already parameterized, as the old parameterization is converted to the new field device type by the database DB or by an application connected to the database DB. Similar to the delivery of the original existing field device, the new field device can be used directly as a new existing field device after installation. The identification information ID is retained, even though a new field device is being used. The new serial number of the new existing field device is linked to the identification information ID. The digital image DT also remains.
[0068] In addition, a reference is added in the database under the identification information ID that the original inventory field device FG has been replaced by a new one.
[0069] In addition, a continuous check can be performed for the existing field device (and / or its successor) to determine whether the currently selected device still matches the current process parameters. The demand information stored in the database Db is updated with the new process parameters. If a significant deviation is detected, a more suitable replacement device can be suggested directly based on the updated demand information (analogous to the replacement described above after the failure of the original existing field device FG).
[0070] The method according to the invention thus makes it possible to link a measuring point of an automation system with numerous unique identification information IDs for various potential and actual field devices throughout its life cycle. This makes it possible to trace at any time which field device was used at this measuring point, at what time, and for what reasons. Furthermore, the device manufacturer can demonstrate why a particular field device was selected, e.g., based on expected process data, ambient temperatures, media, etc.
[0071] List of reference symbols tO, t1 , .... t9 Time points in the process tO', t1', t9' Time points in the process (state of the art) DB Database
[0072] DQ additional data source
[0073] DT digital image of the field device
[0074] FG, FG' existing field device
[0075] ID unique identification information of a (projected
[0076] field device
[0077] KL, KU calibration phase
[0078] LI, Ll' delivery phase
[0079] PD, PD' production phase
[0080] PJ, PJ' Project planning phase SN, SN' Serial number
Claims
Patent claims 1. A method for commissioning, operating and / or maintaining a measuring point in an automation system, comprising: Configuring one or more field devices for use in the measuring point, wherein unique identification information (ID) is generated for the configuration for each field device, wherein each of the unique identification information (ID) is stored with a measuring point identification of the measuring point in a database (DB), wherein requirement information containing information on the application of the measuring point is entered for the configuration, and wherein the requirement information is stored in the database (DB) linked to the unique identification information (ID);Proposals of at least one concrete field device for one or more of the projected field devices based on requirement information, wherein each of the proposed concrete field devices contains a field device type, and in particular a configuration proposal, wherein the proposed concrete field devices are stored in the database (DB) linked to the corresponding unique identification information (ID); Ordering one or more field devices from the set of proposed field devices, whereby a serial number is created for each of the ordered field devices during the ordering process, whereby the serial numbers of the ordered field devices are stored in the database (DB) linked to the corresponding unique identification information (ID); and Installation and commissioning of the ordered field device(s) as an existing field device (FG) or existing field devices (FG) in the measuring point.
2. The method according to claim 1, further comprising: Calibration and / or parameterization of the existing field device (FG), or the existing field devices (FG), prior to installation and commissioning in the measuring point or during installation and commissioning in the measuring point, whereby the calibration and / or parameter data used for calibration and / or parameterization are stored in the database (DB) linked to the corresponding unique identification information (ID).
3. Method according to claim 1 or 2, wherein, during the life cycle of the measuring point, data relating to changes and / or maintenance for each of the existing field devices (FG) are stored in the database (DB) linked to the corresponding unique identification information (ID).
4. The method according to claim 3, wherein the data is one or more of the following: Data sheets from manufacturers, Records of delivery routes, Lifecycle management data, Calibration data, setup / configuration / maintenance data, information on the phasing out of an existing field device (FG) or a field device type, graphic information, design data, in particular CAD data; Maintenance plans, existing and future maintenance costs, Information about the current monetary value, a digital fingerprint, digital records of the state of the asset field device (FG), information about the geographical location.
5. Method according to one of the preceding claims, wherein data linked to the unique identification information (ID) in the database (DB) are provided to a user automatically or upon request.
6. Method according to one of the preceding claims, wherein in the event that a replacement device is required for one of the existing field devices (FG), at least one specific field device is proposed as a replacement field device based on the requirement information linked to the unique identification information (ID) of the existing field device (FG) to be replaced.
7. Method according to one of the preceding claims, wherein at regular intervals or when required, a check is carried out for each of the existing field devices (FG) as to whether the application information contained in the requirement information still corresponds to the current application information, wherein in the event that it is checked for one or more of the requirement field devices (FG) that the application information contained in the requirement information does not correspond to the current application information, at least one specific field device is proposed as a replacement field device for each affected existing field device (FG) based on the current application information.
8. The method according to claim 6 or 7, wherein the replacement field device is calibrated and / or parameterized using the calibration and / or parameter data linked to the unique identification information (ID) of the existing field device (FG) to be replaced.
9. Method according to one of the preceding claims, wherein the data linked to the unique identification information (ID) are linked to respective digital images (DT) of the corresponding inventory field devices (FG).
10. System designed to carry out the method according to one of claims 1 to 9, comprising one or more inventory field devices (FG) and a database (DB).
11. The system of claim 10, wherein the database (DB) is a cloud-based database.
12. System according to claim 10, wherein the database (DB) is a distributed database system composed of individual databases.