Measurement data processing system and process installation
A dual communication network system with Ethernet and bus integration addresses low transmission rates in existing systems, enabling real-time data exchange and enhanced process control through edge computing and AI-driven data fusion, improving precision and flexibility.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ENDRESS HAUSER FLOWTEC AG
- Filing Date
- 2025-10-31
- Publication Date
- 2026-05-15
AI Technical Summary
Existing measurement data processing systems in process automation face limitations due to low transmission rates in bus-based communication networks, which restrict response times and hinder real-time data exchange between field devices, sensors, and process control units.
A dual communication network architecture is implemented, comprising a high-speed Ethernet-based network for data acquisition and processing, coupled with a lower-speed bus network for real-time data transmission, enabling real-time status information generation and transmission via a server platform using edge computing and artificial intelligence for enhanced data fusion.
This approach enhances data transmission rates, allowing for real-time communication of accurate status information as virtual sensors, improving process control precision and reliability while facilitating flexible data processing and integration with cloud services.
Smart Images
Figure EP2025081547_15052026_PF_FP_ABST
Abstract
Description
[0001] Measurement data processing system and process plant
[0002] This invention relates to a measurement data processing system in process automation technology for providing measured variables for an automation technology system and a process plant which includes a measurement data processing system according to the invention.
[0003] Process automation technology utilizes a wide variety of sensors and field devices. These include field devices that measure parameters such as flow rate, flow velocity, fill level, conductivity, pressure, temperature, angle of incidence, or pH value, as well as optical sensors, such as turbidity or absorption sensors. Ion-sensitive sensors, which can detect the nitrate content of a liquid, are also employed.
[0004] A measurement data processing system, often also referred to as a "Manufacturing Execution System" (MES), is a software-based system used, for example, in process automation technology to monitor, control, and optimize production processes. It serves as a link between sensors and field devices on the one hand, and higher-level planning systems on the other. An MES records and documents the transformation of raw materials into finished products and collects data, for example, from equipment, to provide information about its status. This enables efficient resource utilization, improved production planning and control, and higher product quality.
[0005] In a Manufacturing Execution System (MES) for process automation, sensors and field devices are typically connected to a central process control unit via a communication network, often a fieldbus. Many different devices can be connected to this communication network. The process control unit monitors the process by receiving data transmitted by the sensors and field devices, and it controls the process, particularly by controlling devices such as field devices and actuators. The communication network can be, for example, a fieldbus or a bus system that connects sensors, field devices, and actuators within a plant for communication with the process control unit.Communication in the communication network is structured by real-time, which regulates the real-time transmission of data between the devices, i.e., the field devices and actuators, and the process control unit, especially when there are multiple devices.
[0006] Communication participants send their messages over the same line. In this context, real-time refers to the operation of the entire system, consisting of the process control unit, the communication network, and the connected devices, in which programs for processing incoming data, such as measured values and control parameters from field devices, are constantly ready for operation, with the processing results available within a predetermined time period. Depending on the application, this data can be generated randomly over time or at predetermined times. Real-time operation within the communication network requires that the process control unit can only exchange data with the devices one at a time, with data exchange encompassing both transmission and reception.With a large volume of data, it can therefore happen that the devices influence each other within a limited period of time, which can lead to a temporal overlap in data transmission.
[0007] The patent application DE102009029495A1 describes a multi-sensor system used as a field device in process automation technology, which includes a processor for processing input and output signals. This processor is connected to multiple sensors or field devices and is responsible for integrating sensors and actuators into a network that enables efficient and reliable communication between the various components. This is intended to improve process monitoring and control, thereby increasing efficiency and safety.
[0008] The German patent application DE10297009B4 describes a measurement data processing system with multiple process sensors that receive measurement signals which are processed by electronic measurement fusion blocks, a process also known as sensor fusion. Two groups of sensors and corresponding measurement fusion blocks operate independently to generate more accurate and reliable measurements or additional measurement information. All data between sensors and measurement fusion blocks is transmitted via a fieldbus.
[0009] A prior art measurement data processing system capable of processing data from various field devices or sensors, or a comparable prior art system based on a multi-sensor system, suffers from the problem that data transmission between field devices, sensors, or measurement fusion blocks and the process control unit takes place via a bus. This, due to the low transmission rates, limits the response time of a process plant using such systems. The present invention therefore aims to provide a measurement data processing system that enables an increased response time through higher transmission rates of sensor data from a process plant. Furthermore, the measurement data processing system according to the invention is designed to communicate with a process control unit in real time via a communication network.
[0010] The invention solves the present problem with a measurement data processing system according to claim 1.
[0011] The measurement data processing system according to the invention for providing measurement variables for an automation system comprises: a first communication network with a real-time interface; a second communication network; a process control unit, wherein the process control unit is connected to the first communication network; a server platform with a computer unit, a first communication interface and a second communication interface, wherein the server platform is connected to the first communication network via the first communication interface, wherein the server platform is connected to the second communication network via the second communication interface, and wherein the server platform is configured to send and / or receive data in real time;at least one field device configured to acquire measured values of a measured quantity, wherein the at least one field device is connected to the first communication network, wherein the at least one field device is configured to transmit acquired measured values to the process control unit via the first communication network; wherein the at least one field device is configured to transmit data dependent on acquired measured values to the server platform via the second communication network; wherein the computer unit is configured to generate at least one status information about the process and / or about the field device based on the transmitted data; wherein the server platform is configured to transmit the status information generated by the computer unit to the process control unit in real time via the first communication network;wherein the process control unit is configured to process at least one piece of status information.
[0012] In a further development of the measurement data processing system according to the invention, the at least one piece of state information is useful for determining a probability of an event.
[0013] In a further development of the measurement data processing system according to the invention, the at least one piece of state information can be represented as a soft sensor. A soft sensor, also referred to as a virtual sensor or sensor fusion, determines, in particular by means of a dependency simulation, a target variable based on proxy measured variables, wherein the target variable is a function of the proxy measured variables and can be determined based on them, and the proxy measured variables are measured variables acquired by field devices.
[0014] In a further development of the measurement data processing system according to the invention, the at least one state information is a dependency simulation; wherein the dependency simulation is a function of the transmitted data.
[0015] In a further development of the measurement data processing system according to the invention, the generation of the at least one state information includes artificial neural networks and / or multivariate methods.
[0016] In a further development of the measurement data processing system according to the invention, the computer unit determines a state of the at least one field device based on the transmitted data; wherein the at least one state information comprises the determined state of the at least one field device.
[0017] In a further development of the measurement data processing system according to the invention, the computer unit checks the transmitted data for consistency; wherein the status information includes a result of a consistency check of the measured values.
[0018] In a further development of the measurement data processing system according to the invention, the server platform comprises at least one edge computer.
[0019] In a further development of the measurement data processing system according to the invention, the server platform is cloud-based.
[0020] The process plant according to the invention comprises: a measurement data processing system according to one of the preceding claims; actuators configured to influence the process; wherein the process control unit is configured to control the actuators.
[0021] In a further development of the process plant according to the invention, the process control unit controls the actuators based on the state information, in particular automatically. The invention has the advantage that the state information generated in the measurement data processing system can provide insight into the state of field devices, or metadata about a measured value, a measurement environment, and a measurement process. The invention further has the advantage that increased precision and reliability of measurements of measured values of a process variable are achieved by fusing the measurement signals of several field devices. Furthermore, the state information generated in the measurement data processing system is communicated to a process control unit in real time, making the state information available to a user or a process monitoring unit with maximum speed and ease of use.Furthermore, the advantage lies in the fact that the status information generated by the computer unit can be provided to the process control unit as a virtual field device, a soft sensor, or as sensor fusion. Another advantage is that the computer unit generating the status information can be an edge device, which is flexible in its application and thus opens up further application and processing possibilities for the transmitted data, such as a connection to another network like the internet, extended diagnostic capabilities for the field devices, and the integration of artificial intelligence for generating the status information.
[0022] The invention is explained with reference to the following figures. They show:
[0023] Fig. 1 is a schematic sketch of the measurement data processing system, Fig. 2 is a schematic representation of the different clock rates, and Fig. 3 is a schematic representation of the data curves.
[0024] Figure 1 shows a schematic sketch of an embodiment of the measurement data processing system according to the invention, with field devices F1 and F2 connected to a process control unit PS via a first communication network KN1. In this specific embodiment, the first communication network KN1 can be configured as a bus system that connects field devices FG1 and FG2 and actuators AK in a system for communication with an automation device and has transmission rates of 10 kbit / s to 10 Mbit / s. The bus system of the measurement data processing system is, for example, a CAN bus, a Modbus, an AS-Interface, a Foundation® Fieldbus, a HART®, or a comparable system. The field devices FG1 and FG2 are further connected via a second communication network KN2 to a computer unit CE of a server platform SP via a second interface S2.The dotted lines shown in the figure under the field devices FG1, FG2 and the actuator AK indicate that the measurement data processing system may include further field devices and actuators.
[0025] In this configuration, the server platform SP comprises, in addition to the computer unit CE and the second interface S2, a first interface S1, and can further include processor units, memory units, gateways, and cooling systems. The server platform can be cloud-based and accessible via the internet, or designed as part of the process plant.
[0026] The second communication network KN2 can, for example, be a PROFIBUS, a PROFINET, or an Ethernet / IP network and, in this configuration, has a significantly higher data transmission rate than the first communication network KN1, for example, more than 10 Mbit / s, in particular more than 100 Mbit / s, and preferably 1 Gbit / s. In this configuration, the computer unit CE is an edge computer configured to acquire and store data D transmitted by the field devices FG1 and FG2, and to process this data into status information ZI using an algorithm, software, program, or application.
[0027] The status information ZI is transmitted from the computer unit CE via the first interface S1 of the server platform SP to the first communication network KN1, and finally to the process control unit PS. The computer unit CE is configured to transmit the status information ZI in real time EZ, specifically using the real-time EZ applicable to the first communication network KN1, so that this status information ZI can be used by the process control unit PS as a virtual field device, specifically as a soft sensor.
[0028] In the event that no new or current data D is available to the computer unit CE within a time interval of the real-time EZ of the first communication network KN1, the computer unit CE may be configured to transmit alternative data. This alternative data may include, for example, a preset value or a status information ZI from the past.
[0029] Figure 2 schematically illustrates the various clock rates occurring in this embodiment of the measurement data processing system according to the invention. Figure 2 has three horizontal axes, all of which are referenced to a system time. The system time can be provided, for example, by a real-time clock or by a Precision Time Protocol. Figure 2 also includes a vertical axis, which serves to arrange three rows one below the other, and rectangles of different lengths corresponding to data packets, wherein the length of a rectangle corresponds to a transmission duration and is optionally proportional to a typical amount of information in the data packet.
[0030] The line labeled "Measurement signal" represents the temporal sequence of the first data packets D1, typically transmitted between the sensor and transmitter of a field device F1, F2, in system time. These data packets comprise measurement signals acquired by the field device F1, F2 and transmitted to the first communication network KN1. The measurement signals are acquired by the field device F1, F2 with a sampling time AZ, which is determined by the clock of the measurement and operating circuitry of the field device F1, F2 and depends on the device type. For example, sampling times AZ for field devices used in high-speed processes can be in the microsecond range, whereas for field devices used in more typical industrial applications, sampling times AZ range from 0.01 ms to 10 ms, although certain field devices for specific processes may have longer or shorter sampling times AZ.
[0031] The line labeled "Bus" represents the temporal sequence of second data packets D2, typically routed in the first communication network KN1, within the system time. These data packets are clocked with a real-time EZ (interval time) from the first communication network KN1. For example, the data packets are transmitted from at least one field device F1, F2 to the process control unit PS. In this specific example, one data packet of the second data packets D2 contains the information from three data packets of the first data packets D1, which comprise measurement signals acquired by a measuring device F1, F2. The real-time EZ in this configuration is in the range of 1 to 10 ms.
[0032] The line labeled "Ethernet" represents the temporal sequence of third data packets D3, typically routed in the second communication network KN2, within the system time. These data packets are temporally irregular, meaning they have varying lengths and correspondingly different amounts of information, as well as varying time intervals. The information underlying the third data packets D3 includes the measurement signals and can also include data acquired by the field devices F1 and F2, as well as metadata generated by the measurement and operating circuitry of the field devices F1 and F2. The advantage of the third data packets D3 transmitted via Ethernet is that they can be sent at a very high clock frequency and that large amounts of information can be transmitted quickly.
[0033] In this embodiment of the invention, the computer unit CE receives one of the third data packets D3 from the field devices F1, F2 via the second communication network KN2 at irregular system times and generates a status information ZI from it. This status information ZI is then fed into the first communication network KN1 at real-time EZ. If no third data packet D3 is available at a given real-time EZ clock cycle, the computer unit CE is configured to transmit alternative data instead of a status information ZI. This alternative data could, for example, be a predefined ready signal or the most recently determined status information ZI. In this way, continuous real-time EZ data transmission to the process control unit PS is ensured.
[0034] Figure 3 schematically illustrates a configuration of the data flows in the measurement data processing system. It shows that the process control unit (PS) exchanges data (D) with actuators (AK), that the process control unit exchanges data (D) and / or status information (ZI) with the server platform (SP), and that the process control unit (PS) exchanges data (D) and / or measured values (MW) with field devices (FG1, FG2), where exchanging data (D) includes transmitting and / or receiving data (D). In this specific configuration, the data (D) can consist of first data packets (D1), second data packets (D2), and third data packets (D3). In this specific configuration, data (D) can be exchanged via a first communication network (KN1, not shown here) and / or a second communication network (KN2, not shown here).
[0035] Reference symbol list
[0036] KN1 First Communication Network
[0037] EZ Real-time
[0038] Sampling time AZ
[0039] KN2 Second Communication Network
[0040] PS Process Control Unit
[0041] SP Server Platform
[0042] CE Computer Unit
[0043] 51 First communication interface
[0044] 52 Second communication interface
[0045] D data
[0046] D1, D2, D3 First, second, third data packet
[0047] F1 Field Device 1
[0048] F2 Field Device 2
[0049] MW measured values
[0050] ZI status information
[0051] AK Actuators
Claims
Patent claims 1. Measurement data processing system for providing measurement variables for a plant of the Automation technology, comprehensive: • A first communication network (KN1) with a real-time (EZ); • A second communications network (KN2); • A process control unit (PCU), o Where the process control unit (PCU) is connected to the first communication network (KN1); • a server platform (SP) with a computing unit (CE), a first communication interface (S1) and with a second communication interface (S2), o wherein the server platform (SP) is connected to the first communication network (KN1) via the first communication interface (S1), o wherein the server platform (SP) is connected to the second communication network (KN2) via the second communication interface (S2), o wherein the server platform (SP) is configured to send and / or receive data (D) in real time (EZ); • at least one field device (F1, F2) configured to acquire measured values (MW) of a measured quantity, wherein the at least one field device (F1, F2) is connected to the first communication network (KN1), wherein the at least one field device (F1, F2) is configured to transmit acquired measured values (MW) to the process control unit (PS) via the first communication network (KN1); wherein the at least one field device (F1, F2) is configured to transmit data (D) dependent on acquired measured values (MW) to the server platform (SP) via the second communication network (KN2); • wherein the computer unit (CE) is configured to generate at least one status information (ZI) about the process and / or about the field device (F1 , F2) based on the transmitted data (D); • wherein the server platform (SP) is configured to transmit the status information (ZI) generated by the computer unit (CE) to the process control unit (PS) in real time (EZ) via the first communication network (KN1); • wherein the process control unit (PS) is configured to process at least one state information (ZI).
2. Measurement data processing system according to claim 1, • where at least one piece of information (PI) is used to determine the probability of an event.
3. Measurement data processing system according to one of claims 1 or 2, • where at least one state information (ZI) can be represented as a soft sensor.
4. Measurement data processing system according to one of claims 1 to 3, • where at least one state information (SI) is a dependency simulation; • where the dependency simulation is a function of the transmitted data (D).
5. Measurement data processing system according to one of claims 1 to 4, • where generating the at least one state information (ZI) includes artificial neural networks and / or multivariate methods.
6. Measurement data processing system according to one of claims 1 to 5, • wherein the computer unit (CE) determines a state of the at least one field device (F1, F2) based on the transmitted data (D); • wherein the at least one state information (ZI) includes the determined state of the at least one field device (F1, F2).
7. Measurement data processing system according to one of claims 1 to 6, • wherein the computer unit (CE) checks the transmitted data (D) for consistency; • where the status information (ZI) includes a result of a consistency check of the measured values (MW).
8. Measurement data processing system according to one of claims 1 to 7, • where the server platform (SP) includes at least one edge computer.
9. Measurement data processing system according to one of claims 1 to 8, • where the server platform (SP) is cloud-based.
10. Process plant, comprising: • Measurement data processing system according to one of claims 1 to 9; • Actuators (AC) designed to influence the process; • wherein the process control unit (PS) is configured to control the actuators (AK).
11. Process plant according to claim 10, • wherein the process control unit (PC) controls the actuators (AC) based on the status information (SI), in particular automatically.