Method for configuring and commissioning one or more automation technology field devices

Abstract

The invention discloses a method for configuring and commissioning one or more automation technology field devices, comprising: calculating a model based on at least one first parameter and at least one second parameter; computing at least one third parameter from the model; generating an expected input-output table for the measurement process from the model; commissioning the one or more field devices in an industrial plant; as a response to the one or more field devices being commissioned in the industrial plant: generating an actual input-output table for the measuring process; comparing the one or more actual measured values with the one or more expected measured values on a case by case basis; and evaluating a state of the one or more field devices, a state of the at least one first, second, and / or third parameter, and / or a state of the measuring process.

Description

[0001] Procedure for configuring and commissioning one or more field devices in automation technology

[0002] Technical area

[0003] The invention relates to a method for configuring and commissioning one or more field devices in automation technology.

[0004] State of the art

[0005] In the automation industry, the engineering phase is a crucial phase in the development and implementation of automation projects. This phase encompasses the design, planning, and preparation of the automation system to meet the specific requirements of the project. During the engineering phase, the system is often designed based on various process and environmental parameters, especially when it comes to a measurement process that requires more than one field device.

[0006] To ensure the seamless functionality, safety, and operational readiness of a newly installed or modified automation system or device, the automation industry typically follows the following procedure:

[0007] • An industrial process expert plans using engineering software and selects one or more suitable field devices based on a manufacturer’s product manual;

[0008] • During the planning phase, the expert may need to recreate the measurement location and identify the properties of the measured substance and the measurement location that are important for the measurement;

[0009] • The expert makes a printout on paper in order to later communicate the parameters for the field device parameterization to a service technician (who is to install the field devices) of the manufacturer;

[0010] • The expert orders field devices from the manufacturer and the manufacturer builds them in production;

[0011] • The customer receives components of the field devices from the manufacturer; • The service technician installs the field devices at the measurement site, along with a printout on paper detailing the characteristics of the measurement site;

[0012] • The service technician must perform some calculations using a spreadsheet and manually transfer the results (e.g. device-specific parameters) to the field devices until commissioning is completed.

[0013] Technical problem

[0014] Several errors can occur during the procedure described above, for example: the printout from the expert is not available or is available in an incorrect version, the wrong field devices are installed in the wrong place, the calculation of the parameters is incorrect, or the device-specific parameters are transferred incorrectly.

[0015] Task

[0016] The invention is based on the object of developing a method for simplified configuration and commissioning of one or more field devices in automation technology.

[0017] The problem is solved by the method specified in independent claim 1.

[0018] The procedure includes:

[0019] - Calculating a model based on at least one first parameter and at least one second parameter, wherein the at least one first parameter is a process parameter measured by the one or more field devices during the measurement process, wherein the at least one second parameter relates to environmental parameters taken into account when commissioning the one or more field devices,

[0020] - Calculating at least one third parameter from the model, wherein the at least one third parameter is device-specific, - Creating an expected input-output table for the measurement process from the model, wherein the expected input-output table comprises one or more input values ​​and one or more expected measured values ​​corresponding to the respective value or values ​​of the at least one first parameter,

[0021] - Commissioning of the one or more field devices in an industrial plant in which the measurement is carried out, wherein the at least one third parameter is loaded onto the one or more field devices before or during commissioning of the one or more field devices, wherein the one or more field devices are parameterized with the at least one third parameter;

[0022] - In response to the commissioning of the one or more field devices in the industrial plant, creating a real input-output table for the measurement process, wherein the real input-output table comprises the one or more input values ​​and one or more real measured values ​​corresponding to the respective value or values ​​of the at least one first parameter,

[0023] - comparing the one or more actual measured values ​​with the one or more expected measured values ​​on a case-by-case basis, and

[0024] - Evaluating a state of the one or more field devices, a state of the at least one first, second, and / or third parameter, and / or a state of the measurement process.

[0025] Advantageously, the method also comprises calculating an envelope from the model.

[0026] In one embodiment, the at least one first parameter is a measured substance property, including: flow, level, temperature, pressure, viscosity, density, pH, redox potential, conductivity, turbidity, sludge level, concentration, and humidity.

[0027] In one embodiment, the at least one second parameter is a

[0028] Measurement site characteristics, including: shape of the tank, shape of the connected pipes, materials of the tank, materials of the pipes, type of medium, and characteristics of the obstacles in the tank.

[0029] In one embodiment, the expected and real input-output tables are linearization tables.

[0030] In one embodiment, the one or more field devices are installed on one or more coded flange connections.

[0031] In one embodiment, the one or more field devices are mounted on one or more standard flanges having one or more ports that the one or more field devices use to verify their mounting positions.

[0032] In one embodiment, the at least one third parameter is loaded onto the one or more field devices by device configuration software, wherein the device configuration software receives an expected field device group and checks whether the one or more field devices have been correctly connected to one or more expected ports.

[0033] In one embodiment, one or each of the plurality of field devices communicates and exchanges information with other field devices and / or with / via a cloud platform and determines whether the installation positions, the parameterization, and / or the one or more real measured values ​​have been correctly maintained.

[0034] In one embodiment, the at least one first parameter and the at least one second parameter are stored in the cloud platform and are accessible for the configuration and / or commissioning of the one or more field devices.

[0035] This is explained in more detail using the following figures.

[0036] Fig. 1 shows an embodiment of the claimed method. Fig. 2 shows an example of measuring the fill level of a tank filled with cement powder using five field devices.

[0037] Fig. 3 shows a further embodiment of the claimed method.

[0038] In the figures, identical features are identified by identical reference numerals.

[0039] Fig. 1 shows a first example of a procedure for the configuration and commissioning of field devices in an industry.

[0040] To measure a physical quantity in an industrial process, the customer determines at least one first parameter and at least one second parameter during product selection 11. The at least one first parameter and at least one second parameter are then sent to the manufacturer, e.g., to a cloud platform 15 or database of the manufacturer.

[0041] The at least one first parameter is a process parameter measured by the one or more field devices during the measurement process; and the at least one second parameter relates to environmental parameters taken into account during commissioning 14 of the one or more field devices.

[0042] The products are field devices; the one or more field devices are then configured by the manufacturer 12 and delivered to the customer; subsequently, a service technician installs the field devices in the customer's industrial facilities 13; and finally, the service technician adjusts the field devices to ensure that the newly installed field devices are fully functional, safe, and ready for operation 14.

[0043] In the cloud platform 15, a model is calculated based on at least one first parameter and at least one second parameter. At least one third parameter, which is device-specific, is calculated from the model. Furthermore, an expected input-output table for the measurement process is created from the model, wherein the expected input-output table includes one or more input values ​​and one or more expected measured values ​​that correspond to the respective value(s) of the at least one first parameter.

[0044] During commissioning 14, at least one third parameter is loaded onto the field devices and thus the field devices are parameterized.

[0045] In response to the commissioning 14 of field devices, a real input-output table is created for the measurement process, wherein the real input-output table comprises the one or more input values ​​and one or more real measured values ​​corresponding to the respective value or values ​​of the at least one first parameter,

[0046] The one or more real measured values ​​are compared on a case-by-case basis with the one or more expected measured values; and a state of the one or more field devices, a state of the at least one first, second, and / or third parameter, and / or a state of the measurement process are evaluated.

[0047] Referring to Fig. 2, to measure the level of a tank 20 filled with cement powder 21, the customer, who is an expert in the cement industry, recreates the measurement location using engineering software and determines that five radiometric level gauges 201, 202, 203, 204, 205 (each with 20% level increments) are needed for five different measuring points. The five radiometric level gauges 201, 202, 203, 204, 205 can, for example, be five radiometric compact transmitters 201, 202, 203, 204, 205.

[0048] A radiometric measuring device typically consists of at least one gamma emitter 211, 212, which is installed in a radiation protection container, and at least one compact transmitter 201, 202, 203, 204, 205, which calculates measured values ​​of the filling level. The gamma emitter 211, 212 is usually a 137 Cs or 60Co-preparation. Gamma emitters 211, 212 of different activities are selected to suit the respective application. The gamma emitter 211, 212 is installed in a radiation protection container that allows the radiation 210 to exit in only one direction and shields it in all other directions. Different radiation protection containers differ in size and beam exit angle. The compact transmitter 201, 202, 203, 204, 205 contains a scintillator, a photomultiplier, and the evaluation electronics. Incident gamma radiation 210 generates light flashes in the scintillator. These reach the photomultiplier, where they are converted into electrical pulses and amplified. The pulse rate (number of pulses per second) is a measure of the intensity of the radiation 210. The pulse rate is converted by the evaluation electronics into a fill level signal.

[0049] During product selection 11, the expert orders two gamma emitters 211, 212, the associated radiation protection container, and the five compact transmitters 201, 202, 203, 204, 205 from a manufacturer. At the same time, the expert determines the first parameter and several second parameters and sends them to the cloud platform 15 and to the manufacturer.

[0050] The first parameter is the cement level in the tank. The second several parameters are environmental parameters that must be considered when commissioning 14 the field devices, e.g., the shape of the tank, the materials of the tank, the type of measured substance, and the properties of the obstacles 22 in the tank. The properties of the obstacles 22 in the tank must be considered with regard to radiation 210, because a stronger radiation source 211, 212 may then be required for a relevant measuring point.

[0051] A model is calculated based on the information about the first parameter and the second parameter. Several third device-specific parameters are calculated from this model. These third device-specific parameters are later made available to the service technician for parameterizing the compact transmitters 201, 202, 203, 204, and 205. Furthermore, an expected input-output table is created from the model, which includes several input values ​​and several expected measured values ​​of the level. The several input values ​​are, for example, the pulse rates.

[0052] The manufacturer configures 12 the field devices ordered by the expert in production.

[0053] The customer receives field device components from the manufacturer. A service technician installs the field devices at the measurement site 13, eliminating the need to manually enter the device-specific parameters for configuring the compact transmitters 201.

[0054] 202, 203, 204, 205, because the device-specific parameters have already been calculated by the model. During commissioning 14, the device-specific parameters are loaded onto the compact transmitters 201, 202, 203, 204, 205, and the parameterization of the compact transmitters 201, 202, 203, 204, 205 is complete.

[0055] The device-specific parameters can also be loaded onto the compact transmitters 201, 202, 203, 204, 205 before commissioning 34 (Fig. 3), e.g. during configuration 32 of the compact transmitters 201, 202, 203, 204, 205.

[0056] In response to the commissioning 14, 34 of the compact transmitters 201 , 202,

[0057] 203, 204, 205, the compact transmitter 201, 202, 203, 204, 205 creates a real input-output table for the level measurement process. The real input-output table includes several input values ​​of the pulse rates and several real measured values ​​of the level.

[0058] The actual measured values ​​and the expected level measured values ​​are compared on a case-by-case basis. If there is no deviation between the actual measured values ​​and the expected level measured values, or the deviation is within the expected range, the installation (13, 33) of the compact transmitters 201, 202, 203, 204, and 205 is OK. If the deviation is too large or implausible, the installation (13, 33) is incorrect.

[0059] The reason for a large or implausible deviation may be the use of incorrect parameters in the calculation. For example, if the fill level of a material to be measured differs from that of the cement, or if the obstacle 22 in the tank is not correctly taken into account, the calculated device-specific parameters may also be incorrect. The reason for a large or implausible deviation may also be incorrect installation 13, 33 of the compact transmitters 201, 202, 203, 204, 205, including the use of an incorrect compact transmitter. Another reason may be an interim change to the process, e.g., if part of the cement became blocked at one point in the tank during the process, creating a new obstacle.

[0060] It is advantageous to calculate an envelope curve from the model.

[0061] The expected and real input-output tables are advantageous linearization tables.

[0062] It is advantageous to install the compact transmitters 201, 202, 203, 204, 205 on multiple coded flange connections. For example, one flange has one colored line, and a compact transmitter 201, 202, 203, 204, 205 has the same colored line. When installing 13, 33, the colored lines must match. Alternatively, there is a notch on the flange, and the compact transmitter 201, 202, 203, 204, 205 has a raised portion on the flange side. Thus, the compact transmitter 201, 202, 203, 204, 205 can only be installed on the matching flange (otherwise, it will not physically fit the flange if the raised portion / notch on the flange differs). Or instead of colors there is a number on the flange and a number on the compact transmitter 201, 202, 203, 204, 205, which must match (number can be attached to a plate or lasered onto the flange on the device / pipe).

[0063] Advantageously, the compact transmitters 201, 202, 203, 204, 205 are installed on several standard flanges, which feature several connections with which the compact transmitters 201, 202, 203, 204, 205 themselves check their installation positions. The connections can be electrical, inductive, or optical, but are not limited to these. For example, there can be a contact on a flange and a matching plug on a compact transmitter 201, 202, 203, 204, 205; once the compact transmitter 201, 202, 203, 204, 205 is connected to the flange and correctly installed, a colored light illuminates.

[0064] Advantageously, the third device-specific parameters are loaded onto the compact transmitters 201, 202, 203, 204, 205 by device configuration software. The device configuration software receives an expected compact transmitter group and checks whether the compact transmitters 201, 202, 203, 204, 205 have been correctly connected to the expected ports. Advantageously, the compact transmitters 201, 202, 203, 204, 205 exchange information with each other and determine whether the installation positions, parameterization, and / or actual measured values ​​have been correctly maintained. The compact transmitters 201, 202, 203, 204, 205 can also communicate with the cloud platform 15, 35 and exchange information.

[0065] Advantageously, the first parameter and the second parameter are stored in the cloud platform 15, 35 and are accessible for the configuration 12, 32 and / or commissioning 14, 34 of the compact transmitters 201, 202, 203, 204, 205.

[0066] A second example of the method is continuous level measurement using the time-of-flight radar method. In this case, the input values ​​of the expected and actual input-output table are the signal propagation times.

[0067] The examples shown are methods for measuring the fill level, but the invention is also applicable to the measurement of other physical parameters, such as flow, temperature, pressure, viscosity, density, pH, redox potential, conductivity, turbidity, sludge level, concentration and humidity.

[0068] Configuration 12, 32 involves setting up and adapting the software and hardware components of one or more field devices to the specific requirements of the application.

[0069] Installation 13, 33 includes the physical installation and connection of the components (e.g. numerous field devices) of the automation system in the factory or industrial plant.

[0070] Commissioning 14, 34 is the process that ensures that a newly installed or modified automation system or device (e.g., replacement of field devices due to a failure or newer technology) is fully functional, safe, and ready for operation. During commissioning, the automation system is tested, verified, and made ready for operation.

[0071] 11 , 31 Product selection for specific measurement scenarios

[0072] 12, 32 Configuration of field devices

[0073] 13, 33 Installation of field devices

[0074] 14, 34 Commissioning

[0075] 15, 35 Cloud platform

[0076] 20 tanks

[0077] 21 Cement powder

[0078] 22 Obstacle

[0079] 201, 202, 203, 204, 205 compact transmitters

[0080] 211 , 212 gamma emitters

Claims

Patent claims 1. Method for configuring (12, 32) and commissioning (14, 34) one or more field devices (201, 202, 203, 204, 205) of the automation technology, comprising - Calculating a model based on at least one first parameter and at least one second parameter, wherein the at least one first parameter is a process parameter measured by the one or more field devices (201, 202, 203, 204, 205) during the measuring process, wherein the at least one second parameter relates to environmental parameters taken into account during commissioning (14, 34) of the one or more field devices (201, 202, 203, 204, 205), - Calculating at least one third parameter from the model, wherein the at least one third parameter is device-specific, - Creating an expected input-output table for the measurement process from the model, wherein the expected input-output table comprises one or more input values ​​and one or more expected measured values ​​corresponding to the respective value or values ​​of the at least one first parameter, - Commissioning (14, 34) of the one or more field devices (201, 202, 203, 204, 205) in an industrial plant in which the measurement is carried out, wherein the at least one third parameter is determined before or during commissioning (14, 34) of the one or more field devices (201, 202, 203, 204, 205) is loaded onto the one or more field devices (201, 202, 203, 204, 205), wherein a parameterization of the one or more field devices (201, 202, 203, 204, 205) takes place with the at least one third parameter; - In response to the commissioning (14, 34) of the one or more field devices (201, 202, 203, 204, 205) in the industrial plant, creating a real input-output table for the measurement process, wherein the real input-output table comprises the one or more input values ​​and one or more real measured values ​​corresponding to the respective value or values ​​of the at least one first parameter, - comparing the one or more actual measured values ​​with the one or more expected measured values ​​on a case-by-case basis, and - Evaluating a state of the one or more field devices (201, 202, 203, 204, 205), a state of the at least one first, second, and / or third parameter, and / or a state of the measurement process.

2. Method according to claim 1, characterized in that the method further comprises calculating an envelope curve from the model.

3. Method according to at least one of claims 1 to 2, characterized in that the at least one first parameter is a measured material property, comprising: flow, level, temperature, pressure, viscosity, density, pH, redox potential, conductivity, turbidity, sludge level, concentration, and humidity.

4. Method according to at least one of claims 1 to 3, characterized in that the at least one second parameter is a measuring location property, comprising: shape of the tank, shape of the connected pipes, materials of the tank, materials of the pipes, type of measuring substance, and properties of the obstacles in the tank.

5. Method according to at least one of claims 1 to 4, characterized in that the expected and real input-output tables are linearization tables.

6. Method according to at least one of claims 1 to 5, characterized in that the one or more field devices (201, 202, 203, 204, 205) are installed on one or more coded flange connections.

7. Method according to at least one of claims 1 to 6, characterized in that the one or more field devices (201, 202, 203, 204, 205) are installed on one or more standard flanges on which one or more connections are located with which the one or more field devices (201, 202, 203, 204, 205) themselves check their installation positions.

8. The method according to at least one of claims 1 to 7, characterized in that the at least one third parameter is loaded onto the one or more field devices (201, 202, 203, 204, 205) by device configuration software, wherein the device configuration software receives an expected field device group and checks whether the one or more field devices (201, 202, 203, 204, 205) have been correctly connected to one or more expected ports.

9. Method according to at least one of claims 1 to 8, characterized in that the one or more field devices (201, 202, 203, 204, 205) communicate with each other and / or with / via a cloud platform (15, 35) and exchange information and determine whether the installation positions, the parameterization, and / or the one or more real measured values ​​were correctly maintained.

10. The method according to at least one of claims 1 to 9, characterized in that the at least one first parameter and the at least one second parameter are stored in the cloud platform (15, 35) and are accessible for the configuration (12, 32) and / or the commissioning (14, 34) of the one or more field devices (201, 202, 203, 204, 205).

Images