Method for commissioning a new automation field device
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ENDRESS HAUSER PROCESS SOLUTIONS AG
- Filing Date
- 2025-11-28
- Publication Date
- 2026-06-25
AI Technical Summary
The commissioning process for new field devices in industrial plants is time-consuming and inefficient due to numerous isolated, non-integrable steps, leading to a loss of contextual information and repeated efforts in planning and installation.
A method utilizing digital twins for field devices, where a digital representation is created during planning, allowing automatic design and configuration, with a compatibility check post-installation to ensure the physical device matches the digital twin, enabling centralized information management and reuse.
Simplifies the commissioning process by enabling automatic design and configuration, reduces effort, and ensures optimal initial setup through centralized information management using digital twins.
Smart Images
Figure EP2025084632_25062026_PF_FP_ABST
Abstract
Description
[0001] Procedure for commissioning a new field device in automation technology
[0002] The invention relates to a method for commissioning a new field device for automation technology.
[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] The process for planning such an industrial plant, particularly procurement, installation, and commissioning, currently consists of numerous individual, non-integrable, highly specialized, and isolated steps. This can lead to a significant loss of contextual information, which cannot be used to improve these processes. This results in repeated additional effort due to the constant need to gather information. Since a large number of different field devices are used, this process is time-consuming. Each field device comprises a multitude of components with countless options and combinations. Each field device must be planned and commissioned individually.
[0006] US2021 / 0109837 A1 describes a method in which field devices are assigned digital twins. A digital twin is created from an installed field device and assigned to it. Changes made to the parameterization and / or configuration of a field device are also stored in the digital twin.
[0007] Based on this problem, the invention aims to simplify the commissioning of a new field device from the planning phase onwards.
[0008] The task is defined by a procedure for commissioning a new field device in automation technology, comprising:
[0009] - Planning the field device, wherein planning includes creating a digital representation of the field device and designing the field device, wherein design includes: i. Inputting at least one application piece of information or desired property of the field device; ii. Determining a configuration or at least one parameter value derived from the input application piece of information or desired property; iii. Adding the determined configuration or parameter value to the digital representation; iv. If necessary, repeating steps i. to iii. for further application piece of information and / or further desired properties of the field device;
[0010] - Ordering the field device, wherein a physical field device is manufactured according to the configuration determined during the design phase and delivered to the customer; and - Installation and commissioning of the physical field device at the customer's site, including verification that the physical field device matches the digital representation, and, if the physical field device matches the digital representation, transferring information contained in the digital representation, in particular the parameter values, to the physical field device.
[0011] The method according to the invention enables the automatic design of a new field device and the determination of an optimal initial configuration based on contextual or application information already during the planning phase. The required configurations and parameter values can be derived automatically and always in an optimized manner from the application information.
[0012] The optimal initial configuration is first created on a digital twin (also called a "digital twin"). After the physical field device is installed, a compatibility check is performed to ensure it meets the requirements. Any deviations from the design are immediately detected. If the check is successful, the parameters of the digital twin are automatically applied to the physical twin. Thus, the design and optimal configuration of the field device are completed in a single process.
[0013] By using the digital twin, the information is preserved. When building an entire plant, the application information can be used centrally, or the information from the digital twins can be reused, thus reducing the overall effort.
[0014] Configuration refers to the entirety of the hardware and software components of a field device. Parameters are properties by which the (measurement) behavior can be defined by assigning parameter values to the individual parameters. Field devices described in connection with the method according to the invention have already been mentioned as examples in the introductory part of the description.
[0015] According to an advantageous embodiment of the method, the verification includes comparing a serial number between the physical field device and its digital twin. This verifies whether the digital twin and the real field device match. Subsequently, it can be verified whether the determined configuration contained in the digital twin corresponds to the configuration of the physical field device.
[0016] An advantageous embodiment of the procedure provides that the steps of planning the field device and / or verifying it are carried out on a cloud-based platform or by an application running on the cloud-based platform. A cloud-based platform consists, in particular, of one or more servers that are accessible via the internet. One or more (software) applications can be executed on the cloud-based platform, which can be used by a user and which, for example, allow the processing of user data.
[0017] It can be advantageous to store the digital twin on the cloud-based platform. The digital twin can then be used and managed by the applications.
[0018] A method according to any of the preceding claims, wherein a computer algorithm is used for the step of determining the configuration or at least one parameter value. This computer algorithm is executed, in particular, by the cloud-based platform or the application. The computer algorithm was previously trained using a large number of training data. The training data contains both input and output data. The input data consists, in particular, of known application information or properties of a large number of training field devices. The output data consists of configurations or parameter values that the training field devices exhibit with the known application information or properties.The AI algorithm learns a relationship between the input data and the output data through the training data. A neural network is particularly suitable as an AI algorithm, which has an input layer with one or more inputs, an output layer with one or more outputs, and a sufficient number of intermediate layers.
[0019] Advantageously, the application information may include one or more of the following:
[0020] - Information about a region or country in which the field device is to be used;
[0021] - Information about the industry or type of industry in which the field device is to be used;
[0022] - Information about a plant and / or a measuring point where the field device is to be used;
[0023] - Customer information;
[0024] - Information on at least one product being manufactured.
[0025] Desired properties of the field device include, for example, certifications (Ex, SIL, etc.), measurement properties (e.g., measurement accuracy), communication properties (fieldbus type, etc.), or similar.
[0026] The invention is explained in more detail with reference to the following figures. They show
[0027] Fig. 1: a schematic representation of one embodiment of the method according to the invention; and
[0028] Fig. 2: a flowchart of one embodiment of the method according to the invention.
[0029] Figure 1 shows a schematic diagram of a measuring point (MS) in plant A of the process automation system. Measuring point MS is currently in the planning phase and is intended to be part of plant A. During the planning phase, the planning personnel define specific requirements for measuring point MS, which are then used to design the measuring point. For example, it is specified that measuring point MS relates to an application in which a measuring medium is provided, the chemical and physical properties of which are to be checked.
[0030] Two field devices, FG1 and FG2, are to be located at the measuring point. Each field device, FG1 and FG2, is to be in communication with a higher-level PLC via a 4-20 mA current loop or, alternatively, a fieldbus. The PLC queries the measured values from 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).
[0031] The method according to the invention deals with the aspect of the design of the field devices FG1 and FG2. In the present example, the process of planning the field device FG1 from planning to commissioning is described (see flowchart in Fig. 2):
[0032] The field device FG1 is intended to determine the pH value of a measuring medium. In the first process step (1), the field device FG1 is planned. For this purpose, a user (for example, the customer who owns the system, a customer employee, or an employee of the field device manufacturer) accesses a cloud-based platform CP of the field device manufacturer. They use a computer unit RE, which receives internet access to an application SA1 running on the cloud-based platform CP.
[0033] A new project is created for field device FG1 in application SA1. This simultaneously creates a digital twin DA1 of the (still virtual) field device FG1 and stores it in application SA2 (for example, an asset management application). Application AP1 then guides the user through the configuration of field device FG1.
[0034] In the first sub-step (i.), application information is requested, such as information about a region or country in which the field device FG1 is to be used, information about an industry or type of industry in which the field device FG1 is to be used, information about a plant and / or a measuring point in which the field device FG1 is to be used, customer information, or information about at least one product being manufactured. Alternatively or additionally, desired properties of the field device FG1 can be requested, for example, regarding its measurement characteristics.
[0035] In substep ii, the application SA1 uses a computer algorithm to determine a configuration, or part of the configuration, or at least a parameter value for the field device FG1 based on the aforementioned application information or the desired property. This determined information is stored in the digital image DA1 in substep iii.
[0036] Substep iv. represents a repetition of substeps i. to iii. until all application information and desired properties have been entered, the corresponding parts of the configuration and / or parameter values have been determined and stored in the digital image DA1.
[0037] In process step 2.), the order for the field device FG1 is then placed and the field device FG1 is manufactured with the determined configuration.
[0038] In process step 3.), the field device FG1 is delivered to the customer and installed in the measuring point MS of the plant A.
[0039] In process step 4), the field device FG1 is commissioned. For this, a compatibility check is performed between the field device FG1 and its digital twin DA1. The user accesses the cloud-based platform again for this purpose. A preliminary check verifies whether the serial numbers of both units match. If so, it is checked whether the configuration of the physical field device FG1 matches the configuration stored on its digital twin DA1. Specifically, the user enters the individual configuration components of the physical field device FG1 via the processing unit, scans the delivery note for the field device FG1, or takes one or more photos of the physical field device FG1. The scan or photos are transmitted to the cloud-based platform CP, which performs a comparison.
[0040] If compatibility is successfully verified, the physical field device FG1 is synchronized with its digital representation DA1. During this process, the parameter values stored on the digital representation DA1 are transferred to the physical field device FG1, for example, via the computer unit RE or an operator panel that has access to the digital representation DA1. This procedure is then repeated for the second field device FG2, with the digital representation DA2 being assigned to the second field device FG2.
[0041] Reference symbol list
[0042] A facility
[0043] CP Cloud-based platform DA1, DA2 Digital Images
[0044] FG1, FG2 field devices, components
[0045] KN Communication Network
[0046] LS control center of the facility
[0047] MS measuring point RE computer unit
[0048] SA1, SA2 Software Application
[0049] PLC control unit
[0050] 1.), 2.), n.) Procedural steps i.), ii.), iii.), iv.) Sub-steps of the first procedural step
Claims
Patent claims 1. Procedure for commissioning a new field device (FG1, FG2) of automation technology, comprising: - Planning the field device (FG1, FG2), wherein planning includes creating a digital image (DA1, DA2) of the field device (FG1, FG2) and designing the field device (FG1, FG2), wherein design includes: i. Inputting at least one application piece of information or desired property of the field device (FG1, FG2); ii. Determining a configuration or at least one parameter value derived from the input application piece of information or desired property; iii. Adding the determined configuration or parameter value to the digital image (DA1, DA2); iv. If necessary, repeating steps i. to iii. for further application piece of information and / or further desired properties of the field device (FG1, FG2); - Ordering the field device (FG1, FG2), whereby a physical field device is manufactured according to the configuration determined during the design phase and delivered to the customer; and - Installation and commissioning of the physical field device (FG1, FG2) at the customer's site, whereby a check is carried out to see if the physical field device (FG1, FG2) matches the digital image (DA1, DA2), wherein, in the event that the physical field device (FG1, FG2) matches the digital image (DA1, DA2), information contained in the digital image (DA1, DA2), in particular the parameter values, is transferred to the physical field device (FG1, FG2).
2. Method according to claim 1, wherein the verification comprises comparing a serial number between physical field device (FG1 , FG2) and the digital image (DA1 , DA2).
3. Method according to any of the preceding claims, wherein the steps of planning the field device (FG1 , FG2) and / or checking are performed on a cloud-based platform (CP) or by an application (SA1 , SA2) running on the cloud-based platform (CP).
4. Method according to claim 3, wherein the digital image (DA1 , DA2) is stored on the cloud-based platform (CP).
5. Method according to one of the preceding claims, wherein a Kl algorithm is used for the step of determining the configuration or the at least one parameter value.
6. Method according to claims 5 and 3, wherein the AI algorithm is executed by the cloud-based platform (CP) or the application (SA1, SA2).
7. A method according to any of the preceding claims, wherein the application information comprises one or more of the following: - Information about a region or country in which the field device (FG1 , FG2) is to be used; - Information on an industry or type of industry in which the field device (FG1 , FG2) is to be used; - Information on a plant and / or a measuring point in which the field device (FG1 , FG2) is to be used; - Customer information; - Information on at least one product being manufactured.