Field device and method of diagnosis

Abstract

To achieve the efficiency improvement of diagnosis of a field device.SOLUTION: A field device 20, for carrying out field communication, comprises a storage section 211 that saves a diagnostic script received using field communication, the diagnostic script describing a procedure of diagnosis processing to be executed in the field device 20, and a processor 212 that makes a diagnosis of the field device 20 by executing the diagnostic script saved in the storage section 211. For, example, the processor 212 carries out, by executing the diagnostic script, acquisition of alarm information occurred in the field device 20, update of firmware of the field device 20, acquisition of an internal variable of the field device or zero-point adjustment of the field device.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to field devices and diagnostic methods.

Background Art

[0002] When diagnosing field devices such as pressure transmitters and flow meters, first, the user gives an instruction to the field device to read out the parameters set in the field device to be diagnosed from the field device. Next, in accordance with the instruction from the user, the field device transmits the parameters set in itself to the user. The above processes are repeatedly executed for each parameter to be read out from the field device to be diagnosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when there are a plurality of field devices to be diagnosed, etc., since the user needs to perform diagnosis one by one, it is time-consuming. In addition, when changing the parameters of the field device for changing the operation of the field device or enabling / disabling functions in conjunction with the diagnosis of the field device, since the user manually changes the parameters, it is even more time-consuming and human errors are likely to occur.

[0005] Therefore, the present disclosure proposes a technique capable of improving the efficiency of diagnosing field devices.

Means for Solving the Problems

[0006] The field device of the present disclosure is capable of performing field communication and includes a storage unit and a processor. The storage unit stores a diagnostic script that is a script received using the field communication and describes the procedure of a diagnostic process to be executed in the field device. The processor diagnoses the field device by executing the diagnostic script stored in the storage unit.

Advantages of the Invention

[0007] According to the present disclosure, the efficiency of diagnosing a field device can be improved.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Modes for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, the same parts or the same processes may be denoted by the same reference numerals, and redundant descriptions may be omitted.

[0010] [Embodiment 1] <Configuration of Diagnostic System> FIG. 1 is a diagram showing a configuration example of a diagnostic system according to Embodiment 1 of the present disclosure. In FIG. 1, the diagnostic system 1 includes a host device 10, a first field device 20-1, and a second field device 20-2. The host device 10 and the first field device 20-1 can perform field communication with each other, and the host device 10 and the second field device 20-2 can perform field communication with each other. Hereinafter, the first field device 20-1 and the second field device 20-2 may be collectively referred to as the "field device 20". Examples of the field device 20 include a pressure transmitter, a temperature transmitter, a multi-variable transmitter, a flow meter, and the like.

[0011] <Configuration of Field Device> FIG. 2 is a diagram showing a configuration example of a field device according to Embodiment 1 of the present disclosure. In FIG. 2, the field device 20 includes an arithmetic unit 21, a communication unit 22, a display unit 23, and a sensor 24. The arithmetic unit 21 includes a storage unit 211 and a processor 212. The storage unit 211 includes a diagnostic script storage area 21A and a diagnostic result storage area 21B.

[0012] Examples of the arithmetic unit 21 include an MCU (Micro Controller Unit) and the like. Examples of the storage unit 211 include a memory and the like. Examples of the processor 212 include a CPU (Central Processing Unit) and the like. Examples of the display unit 23 include an LCD (Liquid Crystal Display) and the like.

[0013] The communication unit 22 performs field communication with the host device 10. Examples of the field communication performed between the communication unit 22 and the host device 10 include HART communication, Modbus communication, and the like.

[0014] The sensor 24 detects a predetermined physical quantity and outputs data indicating the detected physical quantity (hereinafter sometimes referred to as "sensor data") to the arithmetic unit 21.

[0015] The processor 212 calculates a process value based on sensor data. Further, the processor 212 performs various calculations based on the data input from the host device 10 via the communication unit 22.

[0016] The process value calculated by the processor 212 is displayed on the display unit 23. Further, the parameters set in the field device 20 are displayed on the display unit 23.

[0017] <Processing procedure in the diagnostic system> FIG. 3 is a diagram showing an example of a processing procedure in the diagnostic system according to Embodiment 1 of the present disclosure.

[0018] In FIG. 3, in step S100, the host device 10 transmits a diagnostic script registered in the host device 10 to the field device 20 in accordance with an instruction from the user. By the process of step S100, the diagnostic script is downloaded from the host device 10 to the field device 20. Before the execution of step S100, the user creates a diagnostic script in which the procedure of the diagnostic process to be executed in the field device 20 is described, and registers the created diagnostic script in the host device 10 in advance. Since only the procedure of the diagnostic process is described in the diagnostic script, the data size of the diagnostic script is small. Therefore, since the load imposed on the field communication by the download of the diagnostic script is small, the operation of the field device 20 is not affected by the download of the diagnostic script.

[0019] Next, in step S105, the processor 212 stores the diagnostic script received by the communication unit 22 in the diagnostic script storage area 21A.

[0020] Next, in step S110, the host device 10 transmits a script execution instruction to the field device 20 according to an instruction from the user. When the user causes the diagnostic script to be executed in the field device 20, for example, the user gives the script execution instruction to the field device 20 via the host device 10 by switching the operation modes of the host device 10 and the field device 20. In order not to affect the operation of the field device 20, it is preferable that the user gives the script execution instruction to the host device 10, for example, not during the operation of the field device 20 but during maintenance such as during regular repair of the field device 20.

[0021] Next, in step S115, according to the script execution instruction received by the communication unit 22 in step S110, the processor 212 executes the diagnostic script stored in the diagnostic script storage area 21A. Here, when the diagnostic script is executed during maintenance of the field device 20, it is assumed that the field communication between the host device 10 and the field device 20 is interrupted during the execution of the diagnostic script. However, since the diagnostic script to be executed in step S115 has already been downloaded at the time of step S105, it can be executed offline. Therefore, the interruption of the field communication during the execution of the diagnostic script does not affect the execution of the diagnostic script.

[0022] Next, in step S120, the processor 212 stores the execution result of the diagnostic script (hereinafter sometimes referred to as the "diagnostic result") and the data obtained by the execution of the diagnostic script (hereinafter sometimes referred to as the "acquired data") in the diagnostic result storage area 21B. Hereinafter, the diagnostic result and the acquired data may be collectively referred to as the "diagnostic result log". After storing the diagnostic result log in the diagnostic result storage area 21B, the processor 212 waits.

[0023] Next, in step S125, the host device 10 transmits permission to transmit the diagnostic result log to the field device 20 according to an instruction from the user.

[0024] Next, in step S130, in accordance with the transmission permission received by the communication unit 22 in step S125, the processor 212 reads out the diagnostic result log stored in the diagnostic result storage area 21B from the diagnostic result storage area 21B, and transmits the read diagnostic result log to the host device 10 via the communication unit 22.

[0025] On the other hand, when the host device 10 that has received the diagnostic result log in step S130 analyzes the diagnostic result log, for example, the user can identify the cause of the failure of the field device 20.

[0026] <Example of Diagnostic Script> FIG. 4, FIG. 5, and FIG. 6 are diagrams showing examples of diagnostic scripts according to Embodiment 1 of the present disclosure. FIG. 4 shows a diagnostic script DSA executed when acquiring alarm information generated in the field device 20. FIG. 5 shows a diagnostic script DSB executed when acquiring internal variables of the field device 20. FIG. 6 shows a diagnostic script DSC executed when performing zero point adjustment of the field device 20. Here, the data format of the diagnostic script executed in the field device 20 is not limited. The diagnostic script may be described, for example, by a list of original commands defined uniquely, or may be described by an existing description method such as JSON or XML. Note that the "original command defined uniquely" may also be referred to as a "unique command". Hereinafter, a case where the diagnostic scripts DSA, DSB, and DSC are described by a list of original commands will be described as an example.

[0027] <Diagnostic Script DSA (FIG. 4)> In FIG. 4, the diagnostic script DSA is formed of five blocks A01 to A05.

[0028] In block A01, the processor 212 records all of the 10 pieces of alarm history information held by the field device 20 in the diagnostic result log.

[0029] Next, in block A02, the processor 212 records the currently occurring alarm information in the diagnostic result log.

[0030] Next, in block A03, the processor 212 checks the content of the alarm information recorded in block A02. If no alarm has occurred, the diagnostic result is set to OK. On the other hand, if an alarm has occurred, the processor 212 sets the diagnostic result to NG and records all the parameters related to the occurrence of the alarm (IMPORTANT_PARAM in the example of FIG. 4) in the diagnostic result log.

[0031] Through the processing of blocks A01 to A03, the recording of parameters in the diagnostic result log is completed.

[0032] Next, in block A04, the processor 212 waits until permission to transmit the diagnostic result log is given from the host device 10. When the transmission permission is received via the communication unit 22, the process proceeds to block A05.

[0033] Next, in block A05, the processor 212 transmits the diagnostic result log to the host device 10 via the communication unit 22.

[0034] Next, in block A06, the processor 212 updates the firmware of the field device 20 by writing the bin file (latest_firm.bin) that has been previously downloaded to the field device 20 into the field device 20.

[0035] <Diagnostic script DSB (FIG. 5)> In FIG. 5, the diagnostic script DSB is formed by five blocks B01 to B05. The diagnostic script DSB, which is executed when acquiring the internal variables of the field device 20, is executed, for example, for trouble shooting when troubles such as the function of the field device 20 not operating as specified occur. As an example of the internal variables of the field device 20, there are temporary variables stored in the storage unit 211 and the like, and data that cannot be directly accessed from outside the field device 20. By executing the diagnostic script DSB shown in FIG. 5, the internal variables before and after the execution of the function (TEST_PROGRAM) implemented by the field device 20 are recorded. This makes it possible to significantly shorten the time required for cause analysis of troubles occurring in the field device 20.

[0036] In block B01, the processor 212 reads out the internal variable data based on the memory address and memory size where the internal variables of the field device 20 are stored, and records the read internal variable data in the diagnostic result log.

[0037] Next, in block B02, the processor 212 executes the function (TEST_PROGRAM) implemented by the field device 20.

[0038] Next, in block B03, the processor 212 reads out the internal variable data after the execution of the function (TEST_PROGRAM) implemented by the field device 20 again, and records the read internal variable data in the diagnostic result log.

[0039] Next, in block B04, the processor 212 waits until permission to transmit the diagnostic result log is given from the host device 10, and when permission to transmit is received via the communication unit 22, the process proceeds to block B05.

[0040] Then, in block B05, the processor 212 transmits the diagnostic result log to the host device 10 via the communication unit 22.

[0041] <Diagnostic script DSC (FIG. 6)> In FIG. 6, the diagnostic script DSC is formed by nine blocks C01 to C09. For example, when the field device 20 is a flow meter, zero point adjustment of the flow meter is often performed during installation or maintenance of the flow meter.

[0042] In block C01, the processor 212 sets an initial value to CNT.

[0043] Next, in block C02, the processor 212 repeatedly executes the processing of blocks C03 to C06 three times.

[0044] In block C03, the processor 212 waits for 3600 seconds to stabilize the flow meter itself and the fluid inside the flow meter.

[0045] Next, in block C04, the processor 212 performs zero point adjustment.

[0046] Next, in block C05, the processor 212 stores the adjustment values ADJ_PARAM1 to 5 (hereinafter sometimes referred to as "zero point adjustment values") calculated in the zero point adjustment in buffers P1 to P5.

[0047] Next, in block C06, the processor 212 increments CNT which is the index of the array. After the processing of block C06, the processing returns to block C03.

[0048] After the processing of blocks C03 to C06 is repeatedly executed three times, in block C07, the processor 212 calculates the average value (hereinafter sometimes referred to as "adjustment value average value") of the three zero point adjustment values stored in each of the buffers P1 to P5 for each buffer of buffers P1 to P5, and sets each calculated adjustment value average value as the final zero point adjustment value to ADJ_PARAM_1 to 5.

[0049] Note that during the processing of blocks C1 to C7, the processor 212 sets all the values obtained in each of the processes of blocks C1 to C7 in the diagnostic result log.

[0050] Next, in block C08, the processor 212 waits until permission to transmit the diagnostic result log is given from the host device 10. When the transmission permission is received via the communication unit 22, the process proceeds to block C09.

[0051] Then, in block C09, the processor 212 transmits the diagnostic result log to the host device 10 via the communication unit 22.

[0052] The above is the description of Example 1.

[0053] [Example 2] [Configuration of Diagnostic System] FIG. 7 is a diagram showing a configuration example of a diagnostic system according to Example 2 of the present disclosure. In FIG. 7, the diagnostic system 2 includes a dedicated device 30, a first field device 20-1, and a second field device 20-2. The dedicated device 30 and the first field device 20-1 can perform field communication with each other, and the dedicated device 30 and the second field device 20-2 can perform field communication with each other.

[0054] In Example 1, the diagnosis of the field device 20 was performed according to an instruction from the user to the host device 10. In contrast, in Example 2, various operations that the user performed in Example 1 are executed by the dedicated device 30 on behalf of the user.

[0055] By doing so, the user can diagnose the field device 20 only by connecting the dedicated device 30 with various operations pre-set to the field communication system. Therefore, when diagnosing the field device 20, the user's work can be reduced and the user's work mistakes can be reduced. Also, since the host device 10 is not involved in the diagnosis of the field device 20, the load on the host device 10 is reduced. In Example 1, the diagnostic result logs obtained from the field device 20 are aggregated in the host device 10, whereas in Example 2, the diagnostic result logs obtained from the field device 20 are aggregated in the dedicated device 30. Therefore, the storage capacity of the host device 10 is not compressed. Furthermore, since the diagnostic result logs are aggregated in the dedicated device 30, data management becomes easier.

[0056] The above is the description of Example 2.

[0057] [Example 3] The parameters used for diagnosis in the diagnostic script may be parameters calculated by analysis using, for example, AI (Artificial Intelligence) or the like. For example, by calculating parameters likely to be related to the soundness of the plant in which the field device 20 is used from the regularly acquired data and diagnosing the field device 20 based on the calculated parameters, there is a possibility that signs of malfunction of the field device 20 can be accurately detected.

[0058] For example, all parameters are acquired in advance from the field device 20 that has been operated for a long period (e.g., 5 years or more), and machine learning is performed using the soundness data of the field device 20 and other data related to the soundness of the field device 20 as teacher data. At this time, a learned model is generated in which all parameters are used for machine learning and an estimated soundness value of the field device 20 is output. However, as preprocessing for machine learning, data not related to soundness (e.g., device name, test parameters, etc.) may be excluded. Examples of the soundness data include, for example, the continuous operation time of the field device 20, the number of errors that occurred in the field device 20, the measured physical quantity in the field device 20 (e.g., fluid type, etc.), the maximum and minimum values of the process values measured by the field device 20, and combinations of these data. For example, since the average error occurrence time can be calculated by dividing the continuous operation time by the number of errors that occurred, it can be said that the higher the average error occurrence time, the higher the soundness of the field device 20.

[0059] By causing the processor 212 to execute a diagnostic script implementing the learned model generated as described above, the parameters of the field device 20 are automatically acquired, and an estimated soundness value of the field device 20 is calculated based on the acquired parameters. The user can consider replacing the field device 20 or the like with reference to the calculated estimated soundness value.

[0060]

[0061] The above describes Example 3.

[0062] As described above, the field device (field device 20 in the embodiment) of the present disclosure is capable of performing field communication and includes a storage unit (storage unit 211 in the embodiment) and a processor (processor 212 in the embodiment). A diagnostic script received using field communication is stored in the storage unit. The diagnostic script describes the procedure of the diagnostic process to be executed in the field device. The processor diagnoses the field device by executing the diagnostic script stored in the storage unit.

[0063] For example, by executing the diagnostic script, the processor acquires alarm information generated in the field device. Also for example, by executing the diagnostic script, the processor updates the firmware of the field device. Also for example, by executing the diagnostic script, the processor acquires internal variables of the field device. Also for example, by executing the diagnostic script, the processor performs zero point adjustment of the field device.

[0064] In this way, by previously storing in the field device a diagnostic script describing the procedure of the diagnostic process to be executed in the field device, the user does not need to directly operate the field device during the diagnosis of the field device. Therefore, it is possible to reduce the man-hours of the user and reduce human errors in the diagnosis of the field device. Thus, by the processor diagnosing the field device by executing the diagnostic script, the efficiency of the diagnosis of the field device can be improved.

[0065] Also, the processor executes the diagnostic script in accordance with an execution instruction of the diagnostic script.

[0066] By doing so, the diagnostic script can be executed at an arbitrary timing of the user.

[0067] Also, some examples of combinations in the technology of the present disclosure are described below.

[0068] (1) A field device capable of performing field communication, comprising: a storage unit that stores a diagnostic script which is a script received using the field communication and describes the procedure of diagnostic processing to be executed in the field device; and a processor that performs diagnosis of the field device by executing the diagnostic script stored in the storage unit.

[0069] (2) The field device according to (1), wherein the processor executes the diagnostic script according to an execution instruction of the diagnostic script.

[0070] (3) The field device according to (1) or (2), wherein the processor acquires alarm information generated in the field device by executing the diagnostic script.

[0071] (4) The field device according to (1) or (2), wherein the processor updates the firmware of the field device by executing the diagnostic script.

[0072] (5) The field device according to (1) or (2), wherein the processor acquires internal variables of the field device by executing the diagnostic script.

[0073] (6) The field device according to (1) or (2), wherein the processor performs zero point adjustment of the field device by executing the diagnostic script.

[0074] (7) The field device according to (1), wherein the processor executes the diagnostic script implementing a learned model generated by machine learning.

[0075] A diagnostic method for a field device capable of performing field communication, wherein a processor included in the field device stores a diagnostic script, which is a script received using the field communication and describes procedures for diagnostic processing to be executed in the field device, in a storage unit, and diagnoses the field device by executing the diagnostic script stored in the storage unit.

Explanation of Signs

[0076] 20-1, 20-2 Field devices 211 Storage unit 212 Processor

Claims

1. A field device capable of performing field communication, a storage unit for storing a diagnostic script received through the field communication, the diagnostic script being a script describing a procedure for a diagnostic process to be executed in the field device; a processor that diagnoses the field device by executing the diagnostic script stored in the storage unit; A field device comprising:

2. The processor executes the diagnostic script in accordance with an execution instruction of the diagnostic script. The field device of claim 1 .

3. The processor executes the diagnostic script to obtain alarm information generated in the field device. The field device of claim 1 .

4. The processor updates firmware of the field device by executing the diagnostic script. The field device of claim 1 .

5. The processor acquires an internal variable of the field device by executing the diagnostic script. The field device of claim 1 .

6. The processor executes the diagnostic script to perform zero point adjustment of the field device. The field device of claim 1 .

7. A method for diagnosing a field device capable of performing field communication, comprising: The processor of the field device storing a diagnostic script in a storage unit, the diagnostic script being a script received using the field communication and including a procedure for a diagnostic process to be executed in the field device; diagnosing the field device by executing the diagnostic script stored in the storage unit; Diagnostic methods.

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