Field Device Failure Compensation with Predictive Substitute Variables
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Solution Overview
Problem
In industrial automation plants, field device failures can lead to costly downtime and unpredictable shutdowns, as existing methods rely on redundant devices that may not be readily available when failures occur.
Innovation Solution
A method utilizing data processing units within communication networks to monitor process values, create historical data, establish substitute variables, and predict failure periods, allowing for predictive maintenance and continuous operation without shutting down the plant by transmitting substitute variables to superordinated units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant field devices are installed to compensate for failures, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy of the failed field device's functionality by using substitute variables from existing operational field devices. Instead of installing physical redundant hardware, the system copies the functional behavior through data substitution, where process variables from alternative sensors are used to replace missing measurements, maintaining process availability without adding physical device complexity
Solution Approach 2:
The patent makes existing field devices serve multiple functions by enabling them to provide substitute variables for failed devices. The same communication network and data processing infrastructure are used both for normal operation and for failure compensation, allowing operational devices to universally serve both their primary measurement function and the backup function for failed devices
2Reliability
If field devices are monitored continuously to predict failures, then reliability is improved, but use of energy and processing load increase
Solution Approach 1:
The patent applies partial monitoring by only activating intensive analysis and substitute variable generation when actual failures are detected or predicted, rather than continuously maintaining full redundancy readiness. The system performs basic monitoring at normal operational energy levels and only engages the full predictive maintenance functionality when needed, reducing overall processing energy consumption while maintaining reliability
Solution Approach 2:
The patent performs preliminary failure prediction through continuous but low-energy monitoring of field device status, and only activates the energy-intensive substitute variable generation and transmission processes when failures are actually predicted or occur. This preliminary detection approach allows the system to prepare for failures without continuously consuming high processing energy
Data Source
AI summary
A method for compensating for a malfunction of a field device, includes monitoring process values transmitted by each field device to a superordinated unit; creating historical data based on the transmitted process values for each field device or the sensor unit; establishing a replacement system based on the historical data, wherein the data processing unit ascertains which process variable of a sensor unit can serve as substitute variable to replace a process variable of a further sensor unit; comparing the current process values of the field device, or the sensor unit, with desired values for precalculating periods of time, in which current process values differ by at least one predetermined value from the desired values; and transmitting the substitute variable to the superordinated unit of the data processing unit during the precalculated periods of time.