Field Device Replacement Configuration via Stored Parameter Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for automatically configuring exchange field devices in process control systems are inefficient and require manual intervention, especially during device replacements, leading to resource-intensive and error-prone processes.
Innovation Solution
A method and configuration provider that automatically retrieve, store, and apply configuration data from existing field devices to new replacements, using a communication system like CANopen-based fieldbus or Industrial Ethernet, enabling automatic identification and configuration of new devices and maintaining lists of known and active devices for efficient resource management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual configuration methods are used for field device replacements, then configuration accuracy can be maintained through human verification, but the process becomes time-consuming and resource-intensive
Solution Approach 1:
The configuration data of the old field device is stored in advance in the configuration provider before the device is replaced. When the new device arrives, the pre-stored configuration data is automatically retrieved and transferred, eliminating the need for manual reconfiguration and ensuring accuracy while reducing time consumption.
Solution Approach 2:
The configuration data from the old field device is copied and transferred to the new field device. The configuration provider creates a duplicate of the original device's configuration parameters and automatically applies it to the replacement device, ensuring configuration accuracy while eliminating manual intervention.
2Productivity
If automatic configuration systems are implemented, then configuration speed and efficiency are improved, but system complexity increases due to additional components like configuration providers
Solution Approach 1:
The configuration provider is designed to perform multiple functions: storing configuration data of old devices, detecting the presence of new devices via registration messages, retrieving appropriate configuration data, and automatically transferring it to new devices. This multi-functionality consolidates what could be multiple separate systems into a single component, improving efficiency while limiting the increase in system complexity.
3Ease of operation
If configuration data is automatically transferred from old to new field devices, then manual effort is reduced, but errors may occur if the wrong configuration data is assigned
Solution Approach 1:
The new field device sends a registration message containing its device information to the configuration provider. The configuration provider uses this feedback information to identify and retrieve the correct configuration data, ensuring accurate matching between devices and their configurations while eliminating manual intervention.
Solution Approach 2:
The configuration provider pre-stores configuration data associated with specific device identifiers before replacement occurs. When a new device registers, the system automatically matches the device information with the pre-stored configuration data, ensuring correct assignment without manual intervention and reducing errors.
Data Source
Figure 1a~1c
Figure 1d~1e
Figure 2
AI summary
The invention relates to a method for the automatic configuration of a field device (FD A) in a process control system (1). The process control system comprises one or more field devices (FD) and a configuration provider (CP). The field devices and the configuration provider are communicatively coupled via a communication system (2). The method comprises: the automatic retrieval and storage of configuration data of the field devices by the configuration provider; the automatic detection of the field device by the configuration provider after a second field device has been removed from the process control system and replaced with the field device; and the automatic configuration of the field device with the stored configuration data of the second field device by the configuration provider.The method further comprises the repeated sending of a notification message from the configuration provider to the field devices in order to make the configuration provider known to the field devices. The method further comprises registering the field devices with the configuration provider. The invention further relates to a corresponding configuration provider, corresponding field devices, and a system comprising a configuration provider and one or more field devices, each configured to carry out the method.