Method and system for carrying out a diagnosis of an automation field device

Abstract

The invention relates to a method for carrying out a diagnosis of an automation field device (FG), wherein: the field device (FG) has a first communication connection (KV1) to a control unit (SPS) via a first communication network; the control unit (SPS) has a second communication connection (KV2) to an edge unit (EE) via the first communication network or a second communication network; the control unit (SPS) has an integration module (IM); and the control unit (SPS) has at least one functional block (FB) comprising a diagnostic functionality of the field device (FG); the method comprising: - receiving an event signal (EV) at the functional block (FB); - in response to the receipt of the event signal (EV), initiating the diagnostic functionality at the field device (FG) by means of the functional block (FB); - carrying out the diagnosis and transmitting a result (ER) of the diagnosis to the integration module (IM); - transmitting the result (ER) of the diagnosis from the integration module (IM) to the edge unit (EE) via the second communication connection (KV2); - detecting field device parameters (PA); and - creating a report (BE) relating to the diagnosis of the field device (FG) by means of the edge unit (EE), wherein the report (BE) comprises the result (ER) of the diagnosis and the detected field device parameters (PA). The invention also relates to a system designed to carry out the method according to the invention.

Description

[0001] Method and system for performing a diagnosis of a field device in automation technology

[0002] The invention relates to a method for performing a diagnosis of a field device of automation technology, wherein the field device is in a first communication link with a control unit, in particular a PLC, via a first communication network, in particular a fieldbus of automation technology, a HART network or an Ethernet-based network, wherein the control unit is in a second communication link with an edge unit via the first communication network or a second communication network, in particular an Ethernet-based network and / or a wireless network, wherein the edge unit is in a third communication link with the field device via the first communication network or a third communication network, wherein the control unit has an integration module, and wherein the control unit implements at least one functional block with a diagnostic functionality of the field device.Furthermore, the invention relates to a system which is designed to carry out the method according to the invention.

[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 used close to the process 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 (DOS) 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] Mobile operating devices are frequently used to operate field devices (e.g., to configure parameters or retrieve data). These are connected to a field device either via cable (e.g., a service interface) or wirelessly (e.g., via Bluetooth). Examples of operating devices include laptops, mobile devices such as smartphones or tablets, or central asset management stations.

[0007] To operate field devices, appropriate operating programs (operating tools) are required. These run either independently on higher-level units or on mobile operating devices (Endress+Hauser FieldCare, PACTware, AMS Fisher-Rosemount, Siemens PDM) or are integrated into control room applications (Siemens PCS7, ABB Symphony, Emerson Delta V). The term "operating" encompasses, among other things, configuring the field device, updating it, and / or querying and visualizing process and / or diagnostic data from the field device. The operating programs use device drivers to create operating commands specific to the field device and to interpret response signals from the field devices. Examples of such device drivers are DTMs (Device Type Managers) or FDI packages.

[0008] In the context of Industry 4.0, or ILOT ("Industrial Internet of Things"), data generated by field devices is often collected directly from the field using network devices, such as "edge devices" or "gateways," and automatically transmitted to a central, cloud-enabled database (also simply called "the cloud") where one or more applications reside. These applications, which offer functions for visualizing and further processing the data stored in the database, can be accessed by users via the internet.

[0009] The device drivers offer the possibility to evaluate, diagnose, and / or verify certain device functionalities. Many modern field devices, for example, enable a self-test, such as within the framework of the "Heartbeat" (a self-test functionality implemented in the applicant's field devices) or SIL ("Safety Integrity Level") functionality. The result of these self-tests, evaluations, etc., is output by the device driver in a report. This report contains the relevant report parameters, i.e., test results, device status, etc. The report is typically sent directly to a printer and printed in physical form. The report is processed, for example, by service personnel, who visually inspect it and then sign it. After signing, the report is scanned or stored physically.

[0010] The self-check can also be triggered via a dedicated function block integrated into a PLC environment. This requires no direct human interaction. In this case, the self-test can be performed automatically, for example, before and after a production batch or a cleaning cycle of the system. The output of the function block is the result of the self-check (e.g., "pass," "fail"). With the function block-based approach, it is not possible to generate a PDF report.

[0011] Based on this problem, the invention aims to enable the creation of a report on a diagnosis of a field device initiated by a functional block.

[0012] The problem is solved by a method according to claim 1 and by a system according to claim 13.

[0013] Regarding the method, it is intended that the method serves to perform a diagnosis of a field device of automation technology, wherein the field device is in a first communication link with a control unit, in particular a PLC, via a first communication network, in particular a fieldbus of automation technology, a HART network or an Ethernet-based network, wherein the control unit is in a second communication link with an edge unit via the first communication network or a second communication network, in particular an Ethernet-based network and / or a wireless network, wherein the edge unit is in a third communication link with the field device via the first communication network or a third communication network, wherein the control unit has an integration module.and wherein the control unit executes at least one functional block with a diagnostic functionality of the field device, comprising:

[0014] Receiving an event signal at the function block;

[0015] In response to receiving the event signal, the function block initiates the diagnostic functionality on the field device;

[0016] Performing the diagnosis and transmitting the diagnosis result to the integration module;

[0017] Transmitting the diagnostic result from the integration module to the edge unit via the second communication link; capturing parameters of the field device; and

[0018] Creating a report regarding the diagnosis of the field device by the edge unit, the report including the result of the diagnosis and the field device parameters recorded.

[0019] The core of the inventive method lies in the fact that while the device diagnosis is initiated by a function block in the control unit, the diagnostic report is generated in an edge unit. For this purpose, the function block outputs a diagnostic result (e.g., "pass," "fail") and transmits this result to the edge unit. The edge unit then generates the report, for example, as a PDF document, from this result and from acquired field device parameters. This does not require any fundamental reconfiguration of the control unit. Only a communication link to the edge unit needs to be established, which is often already in place.

[0020] The integration module is a hardware and / or software solution that is part of the operating electronics of the control unit and, among other things, handles communication with the edge unit.

[0021] A function block, also known as a function module, is a (software) organizational unit within the control unit, comprising one or more inputs, a processing algorithm, and one or more outputs. Function blocks specific to one or more field device types and assigned to one or more field devices in the system are provided by the field device manufacturer.

[0022] Field devices described in connection with the invention are already listed by way of example in the introductory part of the description.

[0023] One variant of the procedure involves the field device parameter acquisition process, which includes the edge unit retrieving the field device parameters from the field device via the third communication link. This retrieval can be passive (using "listener" functionality) or active. In the latter case, the edge unit acts as a (secondary) master, depending on the communication network used.

[0024] A second variant of the procedure provides that the acquisition of the field device parameters includes retrieving the field device parameters from the field device by the function block via the first communication link and forwarding the retrieved field device parameters to the integration module, whereby the integration module forwards the retrieved field device parameters to the edge unit via the second communication link.

[0025] According to one implementation of the procedure, the integration module uses an OPC UA, MQTT, Sparkplug, or REST interface to transmit the diagnostic results and / or the requested field device parameters via the third communication link. Data can be transmitted in a defined format via such a standardized interface. The edge unit can also query this data, with the query following a defined schema and potentially including security information (credentials, etc.).

[0026] According to one implementation of the process, the edge unit is intended to store the report in a storage unit. This storage unit can be part of the edge unit or located externally, for example in an external database or in the cloud.

[0027] According to one embodiment of the procedure, the diagnosis includes a check to determine whether a previously known configuration and / or parameterization of the field device has been changed. The current configuration and / or parameterization of the field device is compared with the known configuration and / or parameterization, and any deviation is recorded in the diagnosis result.

[0028] According to one implementation of the procedure, the edge unit is required to sign the report, specifically with a digital signature. This signature can be assigned to a person or a company.

[0029] According to one embodiment of the method, the field device performs a self-diagnosis, transmitting the diagnostic result to the integration module, or the control unit retrieving the diagnostic result from the field device. Self-diagnoses are implemented in the applicant's field devices as a "heartbeat." Self-diagnoses can also include, for example, diagnoses regarding a SIL functionality.

[0030] Alternatively, the diagnostic procedure is performed by the functional block, whereby performing the diagnostic procedure includes retrieving and processing diagnostic parameters from the field device, and the functional block transmits the result of the diagnostic procedure to the integration module. In this case, the diagnostic parameters are retrieved individually or collectively from the field device and processed in the functional block. According to one embodiment of the procedure, the acquisition of the field device parameters includes the acquisition of one or more of the following parameters:

[0031] A parameter for device identification;

[0032] A parameter defining a date and / or time of the field device;

[0033] A parameter that indicates test coverage in %.

[0034] A parameter that includes the result of the diagnosis;

[0035] A parameter or trend that includes a measure of wear and tear on the field device or a sensor unit of the field device;

[0036] A parameter or trend that includes a deviation from a factory setting of the field device;

[0037] A parameter that includes the reading of an operating hours counter of the field device;

[0038] A parameter or trend containing information regarding an overload of the field device or a sensor unit of the field device, in particular concerning temperature or pressure surges;

[0039] A diagnostic parameter, for example corresponding to an NE107 status;

[0040] A parameter containing a checksum of all adjustable parameters of the field device.

[0041] Additional suitable field device parameters can also be retrieved and used as a basis for the report, or assigned to the report.

[0042] According to one embodiment of the procedure, the event signal is generated by another functional block or by a network participant connected to the control unit and transmitted to the functional block.

[0043] According to one implementation of the procedure, the edge unit transmits the report to a network participant or a server, in particular via email or instant messenger. The report can also be accessed by a user via the edge unit, for example, via a web server on the edge unit.

[0044] With regard to the system, it is provided that the system is configured to carry out the method according to the invention, wherein the system comprises a control unit with at least one functional block and an integration module, a field device, and an edge unit. According to one embodiment of the system, the edge unit is configured as a physical device or as a software component, in particular implemented on a computer unit or on a server.

[0045] The invention is explained in more detail with reference to the following figures. They show

[0046] Fig. 1: a schematic representation of a first embodiment of the method according to the invention; and

[0047] Fig. 1 : a schematic representation of a first embodiment of the method according to the invention.

[0048] Figure 1 shows a field device FG, which is connected to a PLC (Programmable Logic Controller) via a first communication network in a first communication link KV1. The field device FG is, for example, a measuring device for acquiring a physical, chemical, and / or biological quantity from a process engineering procedure, or an actuator unit for setting such a quantity.

[0049] The first communication network is in particular a fieldbus for automation technology, an ethernet-based communication network or a HART network.

[0050] The PLC control unit is, for example, a programmable logic controller. The PLC control unit has an environment (UM) for executing function blocks (FB). These function blocks are used to retrieve and / or process data, particularly data from field devices. Communication with the field devices (FG) takes place via a first communication layer (KS1).

[0051] The function block FB described in this embodiment serves to initiate a diagnostic function on the field device FG. If the function block FB receives an event signal ES at its input, which is sent, for example, by another function block or by a device connected to the PLC control unit, the function block FB initiates the execution of the diagnostic procedure.

[0052] This can basically be done in two ways:

[0053] In the first variant, the function block sends a command to the field device FG, which instructs the field device FG to execute its diagnostic functionality. The field device then performs the diagnostic test (for example, as a self-test in the sense of a "heartbeat" self-diagnosis). For this purpose, the field device FG performs individual tests and processes the results to obtain a final result. After completing the diagnostic test, the field device FG transmits the result (for example, "pass" or "fail") to the function block FB.

[0054] In the second variant, the function block FB commands the execution of the individual tests on the field device FG, receives the results and calculates the result from them.

[0055] Both variants result in the function block FB possessing the result after the diagnosis has been completed. The function block FB forwards the result ER within the PLC control unit to an integration module IM. The integration module IM transmits the result via a second communication link KV2 (especially established via the internet) to an edge unit EE using an interface.

[0056] In this case, the edge unit EE is a physical edge device integrated into the plant network (the first communication network). The edge unit EE exchanges data with the field device FG via a third communication link KV3, established over the first communication network. The edge unit EE has a second communication layer KS2 for communication purposes.

[0057] To generate a report (BE), the edge unit (EE) has a software-based report generator (BE). After receiving the result (ER), the edge unit retrieves one or more field device parameters (PA) from the field device (FG). These include additional information, such as a field device identification and / or the operating hours counter reading. The report generator (BG) then creates a report (BE) regarding the diagnosis. The report (BE) contains the diagnosis result (ER) as well as the queried field device parameters (PA). Additionally, the report (BE) is signed by the edge unit (EE), stored in a memory unit, and made available to and / or sent to a user.

[0058] Fig. 2 shows a second embodiment of the method according to the invention. The second embodiment largely corresponds to the first embodiment, but differs in that the field device parameters PA are not acquired by the edge unit EE, but by the PLC control unit from the field device FG. The acquired field device parameters PA are then transmitted together with the result ER to the edge unit EE via the second communication link. This has the advantage that the edge unit EE does not need to be in communication with the field device FG and can, for example, be established as a software solution on a cloud platform. (Reference numeral list)

[0059] BE Report

[0060] BG Report Generator

[0061] EE Edge unit

[0062] ER result of the diagnosis

[0063] ES Eventsignal

[0064] FB Function Block

[0065] FG Field Device

[0066] IM Integration Module

[0067] KS1, KS2 communication layers

[0068] KV1 first communication link

[0069] KV2 second communication link

[0070] KV3 third communication link

[0071] PA field device parameters

[0072] PLC control unit

Claims

Patent claims 1. A method for performing a diagnosis of a field device (FD) of automation technology, wherein the field device (FD) is in a first communication link (KV1) with a control unit (PLC), in particular a PLC, via a first communication network, in particular a fieldbus of automation technology, a HART network or an Ethernet-based network, wherein the control unit (PLC) is in a second communication link (KV2) with an edge unit (EE) via the first communication network or a second communication network, in particular an Ethernet-based network and / or a wireless network, wherein the edge unit (EE) is in a third communication link (KV3) with the field device (FD) via the first communication network or a third communication network, wherein the control unit (PLC) has an integration module (IM).and wherein the control unit (PLC) executes at least one function block (FB) with a diagnostic functionality of the field device (FG), comprising: Receiving an event signal (EV) at the function block (FB); In response to receiving the event signal (EV), the function block (FB) initiates the diagnostic functionality at the field device (FG); Performing the diagnosis and transmitting a diagnostic result (ER) to the integration module (IM); Transmitting the diagnostic result (ER) from the integration module (IM) to the edge unit (EE) via the second communication link (KV2); Acquisition of field device parameters (PA); and Creating a report (BE) regarding the diagnosis of the field device (FG) by the edge unit (EE), wherein the report (BE) includes the result (ER) of the diagnosis and the field device parameters (PA) acquired.

2. Method according to claim 1, wherein the acquisition of the field device parameters (PA) comprises retrieving the field device parameters (PA) from the field device (FG) by the edge unit (EE) via the third communication link (KV3).

3. Method according to claim 1, wherein the acquisition of the field device parameters (PA) comprises retrieving the field device parameters (PA) from the field device (FG) by the function block (FB) via the first communication link (KV1) and forwarding the retrieved field device parameters (PA) to the integration module (IM), wherein the integration module (IM) comprises forwarding the retrieved field device parameters (PA) to the edge unit (EE) via the second communication link (KV2).

4. Procedure according to one of the previous addresses, wherein the integration module (IM) uses an OPC UA, MQTT, Sparkplug or REST interface to transmit the result (ER) of the diagnosis and / or the called field device parameters (PA) via the third communication link (KV3).

5. Method according to any of the preceding claims, wherein the edge unit (EE) stores the report (BE) in a storage unit.

6. Method according to any of the preceding claims, wherein the diagnosis comprises a check to see if a previously known configuration and / or parameterization of the field device (FG) has been changed.

7. Method according to any of the preceding claims, wherein the Edge Unit (EE) signs the report, in particular with a digital signature.

8. Method according to one of the preceding claims, wherein the diagnosis is performed by the field device (FG) as self-diagnosis, wherein the field device (FG) transmits the result (ER) of the diagnosis to the integration module (IM), or wherein the control unit (PLC) retrieves the result (ER) of the diagnosis from the field device (FG).

9. Method according to any one of claims 1 to 7, wherein the diagnosis is performed by the functional block (FB), wherein performing the diagnosis comprises retrieving and processing diagnostic parameters from the field device (FG), and wherein the functional block (FB) transmits the result (ER) of the diagnosis to the integration module (IM).

10. Method according to any of the preceding claims, wherein the acquisition of the field device parameters (PA) comprises acquiring one or more of the following parameters: A parameter for device identification; A parameter defining a date and / or time of the field device (FG); A parameter that indicates test coverage in %. A parameter that includes the result (ER) of the diagnosis; A parameter or trend that includes a measure of wear of the field device (FD) or a sensor unit of the field device (FD); A parameter or trend that represents a deviation from a factory setting of the field device (FG); A parameter that includes the reading of an operating hours counter of the field device (FG); A parameter or trend containing information regarding an overload of the field device (FG), or a sensor unit of the field device (FG), in particular concerning temperature or pressure surges; A diagnostic parameter, for example corresponding to an NE107 status; A parameter containing a checksum of all adjustable parameters of the field device (FG).

11. Method according to one of the preceding claims, wherein the event signal (EV) is generated by another functional block or by a network participant connected to the control unit (PLC) and transmitted to the functional block (FB).

12. Method according to one of the preceding claims, wherein the edge unit (EE) transmits the report to a network participant or to a server, in particular via email or instant messenger.

13. System configured to perform the method according to any one of claims 1 to 12, wherein the system comprises a control unit (PLC) with at least one function block (FB) and an integration module (IM), a field device (FG) and an edge unit (EE).

14. System according to claim 13, wherein the edge unit (EE) is designed as a physical device or as a software component, in particular implemented on a computer unit or on a server.

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