Field Device Alarm Filtering for Application-Specific Diagnostics
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Solution Overview
Problem
Field devices in automation systems often generate false alarms due to varying process and environmental conditions, requiring application-specific settings that are currently dependent on subjective expert knowledge, leading to inefficiencies and increased costs when devices are reused or replaced.
Innovation Solution
A method to apply application-specific settings to field devices, allowing for the filtering out of tolerable diagnostic messages and storing these settings in the device or a cloud-based platform, enabling optimal adaptation and reducing the need for subsequent changes in higher-level control units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If field devices are equipped with monitoring functions to detect all process deviations, then reliability of process monitoring is improved, but false alarms increase due to varying process conditions
Solution Approach 1:
The patent applies local quality by making the alarm behavior application-specific. Each field device can have its alarm thresholds and diagnostic criteria individually adapted to the local process conditions and requirements of the specific application, rather than using uniform monitoring parameters across all installations.
Solution Approach 2:
The patent implements parameter changes by allowing dynamic adjustment of monitoring parameters such as alarm thresholds, diagnostic limits, and evaluation criteria based on the specific application. These parameters can be modified to match the actual process conditions, reducing false alarms while maintaining reliable monitoring.
2Measurement precision
If application-specific settings are determined by expert knowledge, then measurement precision of diagnostic evaluation is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring field devices with default application-specific settings during manufacturing or initial setup. This allows devices to be deployed with pre-optimized parameters for common applications, reducing the need for complex on-site configuration while maintaining diagnostic precision.
Solution Approach 2:
The patent implements copying by enabling the transfer of application-specific settings from one field device to another. Once optimal settings are established for a particular application, they can be copied and reused across multiple devices in similar applications, reducing configuration complexity and time consumption.
3Loss of information
If field devices generate detailed diagnostic messages for all anomalies, then information completeness is improved, but loss of time for error assessment increases
Solution Approach 1:
The patent applies partial action by selectively generating diagnostic messages based on application-specific relevance. Not all anomalies trigger alarms or detailed diagnostics - only those that are critical for the specific application. This filters out irrelevant information while maintaining completeness of important diagnostic data.
Solution Approach 2:
The patent implements feedback mechanisms that allow the system to learn from historical diagnostic data and operator responses. The field devices can adapt their diagnostic message generation based on feedback about which alarms were actionable versus false alarms, improving the signal-to-noise ratio of diagnostic information over time.
4Productivity
If field devices are reused or replaced without application-specific settings, then productivity is improved, but reliability of diagnostic monitoring deteriorates
Solution Approach 1:
The patent applies universality by designing field devices with configurable application-specific settings that can be adapted to different applications. The devices maintain universal hardware and communication capabilities while allowing software-based customization for specific applications, enabling both rapid deployment and reliable monitoring.
Solution Approach 2:
The patent implements preliminary action by pre-configuring field devices with default settings for common applications during manufacturing. When devices are reused or replaced, these pre-configured settings provide a reliable starting point that can be quickly verified or adjusted, maintaining diagnostic reliability without requiring complete reconfiguration.
Data Source
Figure 1
AI summary
The invention relates to a method for the application-specific setting of a field device (FG), which is installed in a defined application (A) in a process in automation engineering and determines or monitors at least one process variable of a medium, wherein the method comprises the following method steps: - recording at least one diagnostic message, error message or notice about an error message (D), which occurs or has occurred at least temporarily on the field device (FG) at least during a defined interval, - analysing which of the diagnostic messages, error messages and/or notices about the error messages (D) are tolerable and/or plausible in the defined application (A), - assigning an application-specific notice (TP) with regard to tolerability and/or plausibility to each diagnostic message, error message and/or notice about an error message (D) that has arisen in the defined application (A), - clearing the at least one diagnostic message, error message and/or notice about an error message (D), if this is classified as tolerable and/or plausible in the defined application (A), - using the application-specific setting (ASE) of the field device (FG), which clears the at least one diagnostic message, error message and/or notice remedy (D) classified as tolerable and/or plausible.