Method for checking a measurement point in an automation system

Abstract

The invention comprises a method for checking a measurement point (MS) in an automation system, wherein at least one field device (FG1, FG2) for acquiring and / or influencing at least one physical, chemical and / or biological measurement variable is used in the measurement point (MS), said method comprising: - providing target measurement point data (SD), wherein the target measurement point data (SD) comprise requirements for properties and / or the measurement behaviour of the field device (FG1, FG2) and / or geometry data of the measurement point (MS); - acquiring real measurement point data (RD, RD'), which real measurement point data (RD, RD') comprise actual properties and / or the actual measurement behaviour of the field device (FG1, FG2) and / or actual geometry data of the measurement point (MS); and - comparing the real measurement point data (RD, RD') with the target measurement point data (SD) in order to detect a possible deviation of the real measurement point data (RD, RD') from the target measurement point data (SD).

Description

[0001] Method for checking a measuring point in an automation system

[0002] The invention relates to a method for checking a measuring point in an automation system, wherein at least one field device is used in the measuring point for detecting and / or influencing at least one physical, chemical and / or biological measured quantity.

[0003] Field devices are already known from the state of the art and are used in industrial plants. They are widely employed in process automation as well as in manufacturing automation. In principle, field devices are defined as all devices that are used close to the process and that provide or process process-relevant information. Thus, field devices are used to acquire and / or influence process variables. Measuring instruments or sensors are used to acquire process variables. These are used, for example, for measuring pressure and temperature, conductivity, flow rate, pH, level, etc., and acquire the corresponding process variables such as pressure, temperature, conductivity, pH value, level, and flow rate. Actuators are used to influence process variables.These include, for example, pumps or valves that can influence the flow of a liquid in a pipe or the fill level in a container. In addition to the aforementioned measuring devices and actuators, field devices also include remote I / Os, radio adapters, and generally any 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 typically 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 automation systems, such as a PLC (programmable logic controller). The higher-level units are used, among other things, for process control, process visualization, process monitoring, and commissioning of the field devices. The measured values ​​acquired by the field devices, especially sensors, are transmitted via the respective bus system to one (or possibly several) higher-level unit(s). Data transmission from the higher-level unit to the field devices via the bus system is also necessary, particularly for configuring and parameterizing field devices and controlling actuators.

[0006] The complexity of systems in process automation is constantly increasing. More and more system components and field devices are being interconnected. But the field devices themselves are also increasing in complexity and software options (especially ordering options and / or activation codes for functions). This means that field devices often consist of a large number of subcomponents.

[0007] The design of field devices, or even entire measuring points, takes place during the so-called "engineering" phase. Here, particularly when ordering field devices or planning measuring points, a selection is made regarding how a field device should best be set up in operation to obtain the calculated values. The device is then ordered and delivered. Often, the information used by the user for the engineering phase is no longer available later.

[0008] It frequently happens that when installing delivered field devices into an existing or new system, the actual situation or installation parameters differ from those used in the original engineering. In such cases, it is usually very time-consuming to even identify the discrepancy, as the information is no longer available or cannot be attributed to the original device.

[0009] Based on this problem, the invention aims to present a method that enables the validation of measuring points and / or their components after their initial order or modifications.

[0010] The task is solved by a method for checking a measuring point in an automation system, wherein at least one field device is used in the measuring point to detect and / or influence at least one physical, chemical and / or biological measured quantity, comprising:

[0011] - Providing target measurement point data, wherein the target measurement point data includes requirements for the properties and / or measurement behavior of the field device and / or geometry data of the measurement point;

[0012] - Recording of real measurement point data, which includes actual properties and / or the actual measurement behavior of the field device and / or actual geometric data of the measurement point; and

[0013] - Comparing the actual measurement point data with the target measurement point data to detect any deviation of the actual measurement point data from the target measurement point data.

[0014] According to the invention, a deviation of the actual situation from the planned situation can thus be observed, which occurs, for example, when certain properties of the measuring point are insufficiently known during the planning phase or when incorrect assumptions exist. Any potential problem would then become apparent immediately and would not only be noticed over time during the ongoing operation of the measuring point.

[0015] According to one embodiment of the procedure, the provided target measurement point data is to be generated as part of an engineering process during the planning phase of the measurement point and / or during the ordering process of the field device, and / or the target measurement point data is simulated and / or calculated based on application information concerning the measurement point and / or the field device. "Engineering" is understood to mean the design of a field device, i.e., the selection of components of a field device (sensor type, etc.) and / or the definition of parameter values ​​for the field device. Application information includes information on the application (e.g., "flow measurement in a milk tank," etc.), the measurement principle (e.g., flow measurement according to the Coriolis principle, etc.), desired accuracies (e.g., maximum deviation of + / - 1%, etc.), etc.

[0016] It may be possible to add or link the data regarding design and installation position to a unique field device identification information and thus be retrieved for installation (e.g. using a laptop, mobile device, etc.).

[0017] One implementation of the procedure involves a software application performing the comparison step, specifically one running on a cloud-based platform, which uses an AI algorithm for this comparison step. Alternatively, the comparison can be performed using comparison operations (<, >, <=, >=, etc.).

[0018] A cloud-based platform is accessible primarily via the internet and is set up on one or more servers. One or more applications, designed for data processing, for example, can be stored and executed on such a platform.

[0019] The AI ​​algorithm, for example, is a neural network. Specifically, it is a perceptron or feedforward network. Such a neural network has an input layer, an output layer, and sufficient layers (so-called "hidden layers"), each with a multitude of nodes, or neurons, between the input and output layers. The neural network is trained beforehand using suitable training data. This training data consists, for example, of various measurement data points. The AI ​​algorithm learns relationships by being fed this training data. For example, a user can confirm or deny the compatibility of different measurement data points, and the AI ​​algorithm uses this result for training. The input layer has one or more nodes, or neurons, for inputting the various measurement data points.The output layer has one or more nodes which, as a result, confirm or deny a deviation, or output a probability value for a deviation.

[0020] In particular, the step of capturing the actual measurement point data involves a user entering at least some of the actual measurement point data into the software application, with the user typically using a mobile device for this input. The mobile device, such as a smartphone or tablet, or alternatively a laptop or PC, accesses the cloud-based platform and its software application, primarily via the internet. The software application can then provide a corresponding user interface with one or more input fields.

[0021] According to one design of the procedure, it is provided that if a deviation of the actual measuring point data from the target measuring point data is detected, a check is carried out to determine whether the required requirements for the measuring point, in particular regarding measurement accuracy, can still be met.

[0022] According to one aspect of the procedure, if the requirements cannot be met, one or more measures will be proposed to restore compliance. Specifically, one or more of the following measures will be proposed:

[0023] - a re-parameterization of the field device, whereby a parameter set containing at least one parameter value based on the deviation is proposed for the re-parameterization,

[0024] - an exchange of the field device for a replacement field device with modified specifications or an exchange of subcomponents of the field device,

[0025] - an exchange of accessories for the field device,

[0026] - a replacement or modification of components of the measuring point, in particular pipelines, tanks or other field devices.

[0027] Should parameters at the installation site differ from those used for the design, a redesign can be carried out directly to check whether the device can withstand the changed parameters (e.g., radiometry -> changed tank specification (e.g., additional obstacles in the tank, different material, etc.), flow: different flow rates, etc.).

[0028] Accessories are parts that are not directly components of a field device, such as a radiation source in the case of a dosimeter. One embodiment of the method provides that the geometry data of the target measurement point data and the actual measurement point data include geometry data relating to the installation position, in particular the installation height and / or the installation inclination of the field device. Depending on the type of field device, especially level gauges, pressure gauges, or radiometric measuring instruments, the correct installation position is essential for measurement performance.

[0029] According to one embodiment of the method, the geometric data of the target measurement point data and the actual measurement point data relate to one or more plant components, in particular pipelines or tanks. This includes, for example, tank heights and diameters, nominal diameters of pipelines, bends or kinks in pipelines.

[0030] The step of acquiring the actual measurement point data can include capturing an image of the measurement point or field device, particularly using a camera on a mobile device. This image is then transmitted to the software application, from which the actual measurement point data is extracted. The software application can use image recognition algorithms or programs for this purpose. It may be possible to attach a marker, the size of which is known to the software application, to the measurement point and capture it in the image, so that correct geometries of the measurement point can be derived from this reference geometry.

[0031] It can be provided that a control unit, in particular a mobile device or a laptop, displays the geometric data relating to the installation position of the target measurement point. Specifically, a camera unit within the control unit captures a real-time image of the measurement point, which is then created from a model based on the geometric data relating to the installation position of the target measurement point. Using augmented reality, a live image of the system can be overlaid with a virtual target image based on the geometric data. This allows for the rapid detection of differences or deviations. The aforementioned marker can also be attached to the measurement point as a reference geometry.In particular, the display of geometric data relating to the installation position of the target measurement point data is initiated by optically detecting an optical code, especially a QR code, attached to the measurement point or the field device. This optical code can contain information about the measurement point, as well as a command or web link to start the display. The optical code itself can also be used as the aforementioned marker. The optical code can also be applied to the measurement point-specific documentation.

[0032] According to one embodiment of the procedure, the requirements for the properties and / or measurement behavior of the field device, the target measurement point data, and the actual measurement point data relate to a configuration of the field device, particularly with regard to the sensor type or subcomponents. Specifically, configurations of alternative field devices not currently used at the measurement point are recorded as actual measurement point data, and their suitability for use at the measurement point is verified by comparison. This could, for example, eliminate the need for the costly ordering of a new field device if existing, unused field devices can unexpectedly be used for the planned application.

[0033] One embodiment of the procedure stipulates that the requirements for the properties and / or measurement behavior of the field device relate to the target measurement point data and the actual measurement point data, specifically parameters of the measurement medium, in particular its type and / or its physical properties. For example, the properties of the measurement medium might be insufficiently known when designing the field device, yet the device is still designed accordingly. The procedure would then reveal whether there is a deviation from the assumed properties of the measurement medium and, if so, whether the field device is even suitable for a precise measurement as intended.

[0034] According to one embodiment of the procedure, the actual measurement point data is acquired periodically, with a comparison of the actual measurement point data with the target measurement point data being performed after each acquisition. This allows any deviations to be detected not only immediately after commissioning a measurement point or after the installation and commissioning of a field device at the measurement point, but also during ongoing operation. For example, this makes it possible to validate the measurement behavior of the field device with changing measurement media.

[0035] The invention is explained in more detail with reference to the following figure. It shows

[0036] Fig. 1 : an embodiment of the method according to the invention.

[0037] Figure 1 shows a measuring point MS of a process automation system. This consists of system components in the form of a tank AK1 and a pipeline AK2 leading from the tank AKI.

[0038] During the planning phase of the measuring point (MS), the planning staff defines specific requirements for the measuring point and uses them for its design. For example, it is determined that the measuring point (MS) relates to an application in which a beer tank is provided, the volume and flow of which are to be monitored. Accordingly, the measuring point (MS) consists of the tank (AK1) and the pipeline (AK2) for the outflow of the measuring medium (beer).

[0039] The volume of container AK is to be determined metrologically using its fill level. To measure the fill level of tank AK1, a field device FG1 engineer!, for example, a radar level gauge, will be installed on container AK during the planning phase. To measure the flow velocity of the process medium flowing through pipeline AK2 as an outflow from container AK1, the measuring point MS will include a field device FG2, for example, a Coriolis flow meter, which will be installed on pipeline AK2.

[0040] The field devices FG1 and FG2 are designed according to the requirements and receive a specific configuration and parameterization during the ordering process to fulfill the measurement tasks. After production and delivery of the field devices FG1 and FG2, they are installed at the measuring point and commissioned.

[0041] Each of the field devices FG1 and FG2 is connected to a higher-level PLC via a 4-20 mA current loop or, alternatively, a fieldbus. The PLC queries the measured values ​​of the field devices FG1 and FG2 and transmits them to the control center (LS) of the plant via another network segment. The entirety of all network segments (the 4-20 mA current loops or the fieldbus, and the other network segment) is referred to below as the communication network (CN).

[0042] All data relating to the measuring point MS, which were created and used during the planning and design phases, are compiled as target measuring point data (SD) and stored on a cloud-based platform (CP). The target measuring point data (SD) can be supplemented with further data regarding requirements for the measuring point MS, its system components AK1 and AK2, and / or its field devices FG1 and FG2.

[0043] After or during the installation or commissioning of the field devices FG1, FG2, real measuring point data RD, RD' are recorded and transmitted to the cloud-based platform CP.

[0044] On the cloud-based platform, one or more software applications SA are executed which, in particular using a KL algorithm, perform an analysis of the target measurement point data SD and the actual measurement point data RD and are designed to detect a deviation of the actual measurement point data RD, RD' from the target measurement point data SD.

[0045] The following are exemplary descriptions of the method. These descriptions should be considered exemplary. It will be apparent to those skilled in the art that further applications and examples of the method are conceivable, which are not explicitly described below.

[0046] In the first variant, the measuring point data pertains to the geometric data of measuring point MS. Here, the geometric data includes the installation position of the field device FG1 on the tank AK1. The field device FG1 is a radar-based level gauge. The correct installation position is of utmost importance for the proper and intended measurement function of this field device FG1.

[0047] The real-time measurement data (RD) is captured using a camera (KA) on a mobile device (ME), in this case a smartphone. This real-time measurement data (RD) is then transmitted to the cloud-based platform (CP).

[0048] If the software application SA detects a deviation, the incorrect installation position can affect the correct measurement function of the field device FG1. To remedy this, the software application SA sends a 3D model of the measuring point MS to the mobile device ME. The mobile device ME displays the measuring point MS live on its display unit by capturing the measuring point MS with the camera KA. The live image is overlaid with the 3D model, in accordance with augmented reality concepts, and the 3D model shows the correct installation position. This allows a service technician on site to adjust the installation position. The procedure can then be repeated and the correctness of the now adjusted installation position verified.

[0049] The geometry data can also affect the plant components AK1 and AK2. For example, a deviation is detected: the pipeline AK2 has a kink upstream of the field device FG2. This alters the flow profile of the process medium being measured by the field device FG2.

[0050] The SA software application can, as a response to the detected deviation, reconfigure the FG2 field device. For example, certain parameter values ​​of the FG2 field device can be changed to react to the altered flow profile. This parameter change in the field is then carried out by a service technician.

[0051] In a second variant, the measurement point data relates to the behavior or performance of the field devices FG1 and FG2. For example, measured values ​​from field devices FG1 and FG2 can be processed by the control center (LS) and transmitted as real measurement point data (RD) to the cloud-based platform. The system then checks whether the measured values ​​meet the requirements, for example, whether they fall within a predefined range. Further process characteristics can also be recorded and transmitted. This includes, for example, the process medium itself. If this changes over time (for example, in an oil refinery where the proportion of water in the oil-water mixture increases during oil production), this may necessitate a redesign of the corresponding field devices FG1 and FG2.

[0052] All the mentioned variants are not to be understood as alternatives, but can also be examined together in order to obtain a complete picture of the MS measuring point.

[0053] If a service technician needs access to the design specifications of a field device FG1 or FG2, this can be done, for example, via an optical code, such as a QR code. This code is attached to the respective field device FG1 or FG2 and, when scanned with a mobile device, provides a link to the relevant design specifications. The specifications can then be viewed, for example, via a sizing sheet. This link also allows for redesign, recalculation of the specifications in the event of changes to the components of the corresponding field device FG1 or FG2, or simulation of changed values. The simulation enables an estimation of the changed measurement behavior of a field device, or the behavior of the measuring point with a changed field device, before the actual physical change or replacement.

[0054] Reference symbol list

[0055] A facility

[0056] AK1, AK2 plant components CP cloud-based platform

[0057] FG1. FG2 Field devices

[0058] KA Camera

[0059] KN Communication Network

[0060] LS Control Center of the ME Plant Mobile Device

[0061] MS measuring station

[0062] RD, RD' real measuring point data

[0063] SA Software Application

[0064] SD Target measuring point data PLC control unit

Claims

Patent claims 1. Method for checking a measuring point (MS) in an automation system, wherein at least one field device (FG1, FG2) is used in the measuring point (MS) for recording and / or influencing at least one physical, chemical and / or biological measured quantity, comprising: - Providing target measurement point data (SD), wherein the target measurement point data (SD) includes requirements for the properties and / or measurement behavior of the field device (FG1, FG2) and / or geometry data of the measurement point (MS); - Acquisition of real measurement point data (RD, RD'), which includes actual properties and / or the actual measurement behavior of the field device (FG1, FG2) and / or actual geometry data of the measurement point (MS); and - Comparing the actual measurement point data (RD, RD') with the target measurement point data (SD) to detect any deviation of the actual measurement point data (RD, RD') from the target measurement point data (SD).

2. Method according to claim 1, wherein the provided target measurement point data (SD) are created as part of an engineering process during the planning phase of the measurement point (MS) and / or during an ordering process of the field device (FG1, FG2), and / or wherein the target measurement point data (SD) are simulated and / or calculated based on application information relating to the measurement point (MS) and / or the field device (FG1, FG2).

3. Method according to claim 1 or 2, wherein the comparison step is performed by a software application (SA), which software application (SA) is in particular executed on a cloud-based platform (CP), wherein the software application (SA) uses a computer algorithm for the comparison step.

4. The method of claim 3, wherein the step of acquiring the real measurement point data (RD, RD') involves an input of at least a part of the real Measurement point data (RD, RD') is entered into the software application (SA) by a user, the user using in particular a mobile device (ME) for input.

5. Method according to one of the preceding claims, wherein, in the event that a deviation of the actual measuring point data (RD, RD') from the target measuring point data (SD) is detected, a check is carried out to determine whether the required requirements for the measuring point (MS), in particular regarding the measurement accuracy, can still be met.

6. A method according to any of the preceding claims, wherein, in the event that the requirements cannot be met, one or more measures are proposed by means of which the requirements can be met again.

7. The method of claim 6, wherein one or more of the following measures are proposed: - a reparameterization of the field device (FG1 , FG2), wherein a parameter set containing at least one parameter value based on the deviation is proposed for the reparameterization, - an exchange of the field device (FG1 , FG2) for a replacement field device with modified specifications or an exchange of subcomponents of the field device (FG1 , FG2), - a replacement or modification of system components (AK1 , AK2) of the measuring point (MS), in particular pipelines, tanks or other field devices (FG1 , FG2).

8. Method according to one of the preceding claims, wherein the geometry data of the target measurement point data (SD) and the actual measurement point data (RD, RD') comprise geometry data relating to an installation position, in particular comprising an installation height and / or an installation inclination of the field device (FG1 , FG2).

9. Method according to one of the preceding claims, wherein the geometry data of the target measurement point data (SD) and the actual measurement point data (RD, RD') relate to one or more plant components (AK1 , AK2), in particular pipelines or tanks.

10. Method according to claim 8 or 9, wherein the step of acquiring the real measurement point data (RD, RD') comprises taking an image of the measurement point (MS) or the field device (FG1, FG2), in particular by means of a camera (KA) of a mobile device (ME), which image is transmitted in particular to the software application (SA), wherein the real measurement point data (RD, RD') are extracted from the image.

11. Method according to claim 8 or 10, wherein a display of the geometry data relating to the installation position of the target measurement point data (SD) is provided on an operating unit, in particular a mobile terminal (ME) or a laptop, wherein in particular a real image of the measurement point (MS) is taken by means of a camera (KA) of the operating unit, which real image is created from a model based on the geometry data relating to the installation position of the target measurement point data (SD).

12. Method according to claim 11, wherein the display of the geometry data relating to the installation position of the target measuring point data (SD) is initiated by optical detection of an optical code, in particular a QR code, attached to the measuring point (MS) or to the field device (FG1, FG2).

13. Method according to one of the preceding claims, wherein the requirements for properties and / or the measurement behavior of the field device (FG1 , FG2) of the target measurement point data (SD) and the actual measurement point data (RD, RD') relate to a configuration of the field device (FG1 , FG2), in particular with regard to the sensor type or subcomponents.

14. Method according to claim 13, wherein the real measuring point data (RD, RD') are configurations of alternative devices not used in the measuring point (MS). Field devices are recorded and their suitability for use in the measuring point (MS) is checked by means of the comparison step.

15. Method according to one of the preceding claims, wherein the requirements for properties and / or the measurement behavior of the field device (FG1, FG2) of the target- Measuring point data (SD) and the real measuring point data (RD, RD') relate to parameters of the measuring medium, in particular its type and / or its physical properties.

16. Method according to one of the preceding claims, wherein the acquisition of the real Measurement point data (RD, RD') is acquired periodically, with the step of comparing the actual measurement point data (RD, RD') with the target measurement point data (SD) being carried out after each acquisition.

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