DE102016122051A1 - Method and system for determining diagnostic information of at least one field device of process automation - Google Patents

Abstract

The invention comprises a method and a system for determining diagnostic information (INFO) of at least one field device (F1, F2, F3, F4) of process automation, comprising: receiving a diagnostic message of the field device (F1, F2, F3, F4); Diagnostic data record of the field device (F1, F2, F3, F4); storing the diagnostic data record in a data block belonging to the field device (F1, F2, F3, F4); generating an image of the data block in a visualization environment (SCADA); determining at least one corresponding to the diagnostic data record Diagnostic information (INFO) by matching data contained in the image of the data block with a device description data file (GBSD), the device description data collection file (GBSD) containing all diagnostic information (INFO) assignable to the field device (F1, F2, F3, F4); andvisualizing the determined diagnostic information (INFO). Furthermore, the invention comprises a function block (FB498), a faceplate (BB) and an overall reporting window (GF) for use in the system according to the invention.

Description

The invention relates to a method and a system for determining diagnostic information of at least one field device of process automation. Furthermore, the invention comprises a function module, a faceplate and an overall message window, for use in the system according to the invention.

Field devices are already known from the prior art, which are used in industrial plants. Field devices are often used in process automation technology as well as in factory automation technology. In principle, field devices are all devices that are used close to the process and that provide or process process-relevant information. For example, field devices are used to detect and / or influence process variables. Measuring devices or sensors are used to record process variables. These are used, for example, for pressure and temperature measurement, conductivity measurement, flow measurement, pH measurement, level measurement, etc. and record the corresponding process variables pressure, temperature, conductivity, pH value, level, flow etc. Actuators are used to influence process variables. These are, for example, pumps or valves that can influence the flow of a liquid in a pipe or the level in a container. In addition to the measuring devices and actuators mentioned above, field devices are also understood as remote I / Os, radio adapters or general devices which are arranged at the field level.

A large number of such field devices are produced and sold by the Endress + Hauser Group.

In modern industrial plants, field devices are generally connected to higher-level units via communication networks, such as fieldbuses (Profibus®, Foundation® Fieldbus, HART®, etc.). Normally, the higher-level units are control units, such as a PLC (Programmable Logic Controller) or a PLC (Programmable Logic Controller). Among other things, the higher-level units are used for process control and commissioning of the field devices. The measured values acquired by the field devices, in particular by sensors, are transmitted via the respective bus system to one (or possibly several) higher-level unit (s) which, if appropriate, further process the measured values and forward them to the control console of the system. The control station is used for process visualization, process monitoring and process control via the higher-level units. In addition, a data transmission from the higher-level unit via the bus system to the field devices is required, in particular for the configuration and parameterization of field devices and for the control of actuators. The entirety of the higher-level units and the components of the control center is referred to as the process control system.

The SIMATIC PCS7 (PCS stands for "Process Control System") is such a process control system from Siemens. It is based on coordinated hardware and software components. On the hardware side, standard components typically include a PC, a controller, distributed peripherals and communication interfaces. The actual control software is the product of the same name. The name PCS7 stands on the one hand for a complete hardware and software included system, as well as for the pure control software. The control system is operated via the graphical user interface of the WinCC SCADA software integrated in PCS7. SCADA ("Supervisory Control and Data Acquisition") is the monitoring and control of technical processes by means of a computer system

To operate the field devices, corresponding operating programs (operating tools) are required, which run independently on the higher-level units (Endress + Hauser FieldCare, Pactware, AMS Fisher-Rosemount, PDM Siemens) or in applications of the control center (Siemens PCS7, ABB Symphony, Emerson Delta V) are integrated. The term "operating" is understood inter alia to parameterize the field device, to update the field device and / or to interrogate and visualize process data and / or diagnostic data of the field device.

Modern fieldbus-capable field devices are able to provide much more information about devices and processes than the pure measured values, such as diagnostic data. These data, which are available in the device, are rarely or not at all used in the control room of the plant, let alone in higher-level systems at company or company management level, due to a high degree of engineering effort.

In process automation, diagnostics of field devices are very important to find out the causes of certain unwanted symptoms. The more extensive the diagnostics (the entirety of all measures leading to the recognition (diagnosis) of a malfunction) and their evaluation, the more accurately errors can be determined, which minimizes the time of manual troubleshooting. This saves costs for replacing entire systems. Above all, however, downtimes of plants can be minimized and, depending on the case, even prevented.

Today, diagnostics are mainly done in the display of a field device. An automated diagnosis using device-specific diagnostic information at a central point in the process control system often does not take place due to a high level of engineering effort.

Based on this problem, the invention has the object to provide a method and a system which allows to make diagnostic information automatically and easily accessible to a user via the process control system of a system.

• - Empfangen einer Diagnosemeldung des Feldgeräts;
• - Auslesen eines Diagnosedatensatzes des Feldgeräts;
• - Speichern des Diagnosedatensatzes in einem dem Feldgerät zugehörigen Datenbaustein;
• - Erzeugen eines Abbildes des Datenbausteins in einer Visualisierungsumgebung;
• - Ermitteln zumindest einer zum Diagnosedatensatz korrespondierenden Diagnoseinformation durch Abgleichen von im Abbild des Datenbausteins enthaltenen Daten mit einer Gerätebeschreibungssammeldatei, wobei die Gerätebeschreibungssammeldatei alle dem Feldgerät zuordenbaren Diagnoseinformationen enthält; und
• - Visualisieren der ermittelten Diagnoseinformation.

The object is achieved by a method for determining diagnostic information of at least one field device of process automation, comprising:

• - receiving a diagnostic message of the field device;
• - Reading a diagnostic data record of the field device;
• - storing the diagnostic data record in a data block associated with the field device;
• - generating an image of the data block in a visualization environment;
• Determining at least one diagnostic information corresponding to the diagnostic data record by matching data contained in the image of the data module with a device description data file, wherein the device description data collection file contains all diagnostic information that can be assigned to the field device; and
• - visualizing the determined diagnostic information.

The great advantage of the method according to the invention is that diagnostic information can be visualized automatically in the process control system in a simple manner. Upon the occurrence of a diagnostic message of a field device, further steps are taken independently to not only indicate the presence of the diagnostic message, but also to visualize the corresponding diagnostic information.

A data block is used by a control unit for storing data and system states, with the memory space of a data block being up to 8 kilobytes, depending on the control unit used. The control unit holds for each field device connected to its own data block, which is equipped in the presence of a diagnostic message of the respective field device with the read out of the respective field device diagnostic record.

The diagnostic information is a textual description of the problem that has occurred at the field device. For example, a flowmeter may indicate that the maximum temperature of a sample has been exceeded or that an error has occurred in accessing the internal memory of the flowmeter.

Field devices which are mentioned in connection with the method according to the invention are already described by way of example in the introductory part of the description.

According to an advantageous embodiment of the method according to the invention, it is provided that the determined diagnostic information is stored in a log file. The diagnostic data are stored permanently in the log file at runtime. Using the logbook, it is possible within the process control system to access the past diagnosis information determined.

According to a further refinement of the method according to the invention, it is provided that the timeworn and / or network-relevant information of the field device, in particular its identification and / or its network address, is assigned to the determined diagnostic information and stored in the log file. This makes it easy to understand when and where diagnoses of a field device have occurred.

According to a preferred embodiment of the method according to the invention, it is provided that the determined diagnostic information is stored in an XML format or in a text format. While information saved in text format can be easily read by a user, the XML format serves as a transport medium for integrating diagnostic information into components of the control system. In particular, information stored in XML format can be read out from components of the control system and / or be further processed directly by the latter.

According to a particularly preferred embodiment of the method according to the invention, it is provided that the log file components of the control system of a process plant, in which the field device is integrated, is provided. The logbook is exported for this purpose. The components are, in particular, workstation PCs and / or control units. The log file can be used by the respective components and processed directly, in particular when using the XML format. With the help of the logbook, further applications in the context of "Industry 4.0" and / or "Big Data" are conceivable.

In an advantageous development of the method according to the invention, it is provided that device descriptions of a multiplicity of field devices are summarized in advance and stored in the device description collection file. The device descriptions are Profibus device description files in which, according to the current Profibus PA application profile 3.02, the extended device diagnostics of each field device operating according to the profile are broken down. The device description summary file contains all relevant information of the individual device descriptions. A provision of individual device descriptions is not necessary. Incompatibility problems, which can occur when using a large number of separate device descriptions, possibly created by different device manufacturers, are also avoided.

• - eine Steuerungseinheit, welche mit dem jeweiligen Feldgerät in Kommunikationsverbindung steht, wobei die Steuerungseinheit eine Diagnosemeldung des jeweiligen Feldgeräts über den zyklischen Datenverkehr der Kommunikationsverbindung erhält, wobei die Steuerungseinheit derart ausgestaltet ist, einen Diagnosedatensatz des jeweiligen Feldgeräts, welcher gerätespezifische Diagnoseinformationen enthält, auszulesen und diesen Diagnosedatensatz in einem zum jeweiligen Feldgerät gehörigen Datenbaustein zu speichern; und
• - ein auf einer Rechnereinheit ablaufendes Prozessvisualisierungssystem, insbesondere WinCC, wobei das Prozessvisualisierungssystem derart ausgestaltet ist, eine zum Diagnosedatensatz korrespondierende Diagnoseinformation durch Abgleichen von im Abbild des Datenbausteins enthaltenen Daten mit einer Gerätebeschreibungssammeldatei zu ermitteln und die ermittelten Diagnoseinformation zu visualisieren, wobei die Gerätebeschreibungssammeldatei alle dem jeweiligen Feldgerät zuordenbaren Diagnoseinformationen enthält.

With regard to the system, the object is achieved by a system for determining diagnostic data from at least one field device of process automation, comprising:

• - A control unit, which communicates with the respective field device in communication, wherein the control unit receives a diagnostic message of the respective field device via the cyclic data traffic of the communication link, wherein the control unit is configured to read a diagnostic record of the respective field device, which contains device-specific diagnostic information, and read this Store diagnostic data record in a data block belonging to the respective field device; and
• a process visualization system running on a computer unit, in particular WinCC, the process visualization system being designed to determine a diagnosis information corresponding to the diagnostic data record by matching data contained in the image of the data module with a device description data file and to visualize the determined diagnostic information, the device description data collection file all corresponding to the respective one Field device contains diagnostic information.

The great advantage of the system according to the invention is that diagnostic information can be visualized in a simple manner with the aid of already existing system components in the process control system without changing the hardware structure.

An advantageous embodiment of the system according to the invention provides that the field device is configured as a Profibus DP slave and is in communication environment via a Profibus DP fieldbus with the control unit.

According to a preferred development of the system according to the invention, it is provided that the at least one field device is a Profibus PA slave and communicatively connected to a transparent coupling module or a non-transparent coupling module via a Profibus PA fieldbus, the Profibus DP link being connected via a Profibus DP fieldbus with the control unit in communication environment.

In a preferred embodiment of the system according to the invention, it is provided that the process visualization system is configured to store the determined diagnostic information of the respective field device in addition to the visualization in a log file, in particular in an XML format. As already described above, it is possible by means of the logbook outside the process control system to access the diagnostic information determined. With the help of the logbook, further applications in the context of "Industry 4.0" and / or "Big Data" are conceivable.

With regard to the function block, the object is achieved by a function block for use in the system according to the invention, wherein the function block is executable in the control unit and wherein the function block causes the reading of the diagnostic record and storing the diagnostic record in the data block.

A function module is a program which can be executed in a control unit, for example in a programmable logic controller (PLC). To carry out the method according to the invention in the system according to the invention, the functional module according to the invention must be integrated into the control unit.

According to an advantageous embodiment of the function module according to the invention, it is provided that the function module is a STEP7-compatible function module. STEP7 is software for programming PLCs in a SIMATIC PCS7 system from Siemens.

With regard to the faceplate, the object is achieved by a faceplate for use in the system according to the invention, wherein the faceplate is assigned to the respective field device, implemented in the process visualization system, and designed to visualize the determined diagnostic information.

A faceplate refers to a visualization element in the SCADA software in which information is displayed. The faceplate is placed on the process picture displayed in the SCADA software.

According to a preferred embodiment of the faceplate according to the invention, it is provided that the faceplate is a WinCC-compatible faceplate.

According to a particularly preferred embodiment of the faceplate according to the invention, it is provided that, in addition to the determined diagnostic information, the identification of the respective field device, the network address of the field device, the network address of the master of the field device and / or the description of the diagnostic information, also NAMUR NE107-compliant, is visualized , Thus, all information required by the plant operator in connection with the diagnostic information in order to be able to assess the problem or to create a problem solution is visualized.

With regard to the overall message window, the object is achieved by a total reporting window for use in the system according to the invention, wherein the overall message window reads the determined diagnostic information of all field devices from the log file and visualizes the last 50 diagnostic information, in addition to the diagnostic information, the number of the respective diagnostic information, date and time the respective diagnostic information, the identification of the respective field device and / or the network address of the respective field device is visualized. The overall message window represents a special faceplate, which in a simple and clear manner represents a summary of past diagnostic messages and their specific diagnostic information.

• 1: ein Ausführungsbeispiel des erfindungsgemäßen System;
• 2 ein Ausführungsbeispiel des erfindungsgemäßen Verfahrens;
• 3: ein Ausführungsbeispiel des erfindungsgemäßen Bildbausteins; und
• 4: ein Ausführungsbeispiel des erfindungsgemäßen Gesamtmeldefensters.

The invention will be explained in more detail with reference to the following figure. Show it

• 1 an embodiment of the system according to the invention;
• 2 an embodiment of the method according to the invention;
• 3 : an embodiment of the faceplate according to the invention; and
• 4 : An embodiment of the overall message window according to the invention.

1 shows an embodiment of the system according to the invention. Here, a system of automation technology is shown. On a fieldbus D1 , which works according to the Profibus DP standard, are several workstation PCs WS1 . WS2 connected to the control level of the system. Via a control unit SPS , which is a programmable logic controller, is the data bus D1 connected to a fieldbus segment. The workstation PCs connect with the data bus D1 and the control unit SPS the control system of the plant and serve among other things for process visualization, process monitoring and engineering as well as for the operation and monitoring of field devices.

The fieldbus segment consists of several field devices F1 . F2 . F3 . F4 that have a fieldbus FB connected to each other. With the field devices F1 . F2 . F3 . F4 these can be sensors or actuators. The fieldbus FB works according to the fieldbus standard Profibus PA.

2 shows an embodiment of the method according to the invention. This in 1 shown field device F3 , a flowmeter, detects an unusually high proportion of air in the measuring medium based on some sensor parameters. As a result, the flow readings are very inaccurate and no longer informative. The field device F3 indicates in a first method step 1 in the usual cyclic data query to have an error pending. Based on this information, a read request for a function block is made via the object block OB1 FB498 set and started its processing.

In a second method step 2, the control unit reads SPS by processing the function block FB498 Diagnostic data records from the field device F3 out. The function module FB498 also causes these diagnostic data sets in a data block belonging to the field device in the control unit SPS get saved.

In a third method step 3, an image of the data block is stored on a workstation PC WS2 running visualization environment SCADA saved. In the visualization environment SCADA this is in particular WinCC.

In a fourth method step 4, a script processes the visualization environment SCADA the data contained in the data block. The script determines at least one diagnostic information corresponding to the diagnostic data record by matching data contained in the image of the data module with a device description data file gBSD which for this purpose in a fifth method step 5 of the visualization environment SCADA is read.

The device description summary file gBSD is created in advance by the Device descriptions, more precisely Profibus device description files, the field devices F1 . F2 . F3 . F4 are read in a tool and the diagnostic information stored in them about the device description summary file gBSD be joined together. The device description summary file gBSD thus receives all for the field devices F1 . F2 . F3 . F4 available and assignable diagnostic information.

In a sixth method step 6, the determined diagnostic information is stored in a log file LOG saved. In this logfile LOG Diagnostic data is constantly added and stored at runtime. In addition, the diagnostic information determined is a time stamp and / or network-relevant information of the field device F3 in particular its identification and / or its network address, assigned and in the log file LOG saved. This makes it easy to understand, when and where the diagnostic message of the field device F3 originated.

In a seventh method step 7, the log file LOG exported. The diagnostic data for this purpose at runtime in text and XML format from the visualization environment SCADA exported. While information stored in text format can be easily read by a user, the XML format acts as a transport medium for integrating diagnostic information into higher-level systems. In particular, information stored in XML format can be read out by higher-level systems and / or processed further directly by them. For example, a parent system is an ERP (Enterprise Resource Planning) system. With the help of the logbook LOG Further applications in the context of "Industry 4.0" and / or "Big Data" are conceivable.

In an eighth method step 8, the determined diagnostic information is in a faceplate BB and in a total reporting window GF visualized. These components BB . GF be in 3 and 4 described in more detail.

The great advantage of the method according to the invention is thus that diagnostic information can be visualized in a simple manner in the process control system. When a diagnostic message of a field device appears F1 . F2 . F3 . F4 independently further steps 1 to 7 are taken to not only indicate the presence of the diagnostic message, but also to visualize the corresponding diagnostic information.

3 , divided into 3a and 3b, show an embodiment of the faceplate according to the invention BB ,

3a shows the first page of the faceplate BB , the overview page. On this overview page is the day DAY of the respective field device F1 . F2 . F3 . F4 displayed. Under "General" is the current status of the field device F1 . F2 . F3 . F4 and the description B the diagnostic information INFO displayed.

In a table are the last 6 diagnostic information INFO to the faceplate BB belonging field device F1 . F2 . F3 . F4 displayed, in addition to the diagnostic information INFO the number # the respective diagnostic information, date and time DAT the respective diagnostic information, the network address ADD of the respective field device F1 . F2 . F3 . F4 and / or the logical diagnostic address of the field device is visualized as a Profibus DP subscriber.

Furthermore, it is located in the faceplate BB a link element, with the help of which between the first page and the in 3 b) displayed second side of the faceplate can be changed.

3 b shows the second page of the faceplate BB on which extended information about a field device F1 . F2 . F3 . F4 are displayed. First, the identification ID of the field device F1 . F2 . F3 . F4 , and its network address ADD displayed, the other is the description B the diagnostics information is visualized in accordance with NE107. Furthermore, the hexadecimal measured value status of the current main measured value of the field device is displayed F1 . F2 . F3 F4 displayed. As an alternative display method, it is possible to display the read diagnostic data record in hexadecimal format.

4 shows an embodiment of the overall message window according to the invention GF , In contrast to the in 3 shown faceplate BB the overall message window reads the determined diagnostic information of all field devices F1 . F2 . F3 . F4 from the log file LOG out. The total alarm window visualizes the last 50 diagnostic information, in addition to the diagnostic information the number # the respective diagnostic information, date and time DAT the respective diagnostic information, the identification ID of the respective field device F1 . F2 . F3 . F4 and / or the network address ADD of the respective field device is visualized. The overall message window is a special message window that summarizes past diagnostic messages and their specific diagnostic information in the visualization environment in a simple and clear manner SCADA represents.

It goes without saying that the inventive method and the system according to the invention on any type and number of field devices F1 . F2 . F3 . F4 is applicable and not on the in the figures 1 - 4 shown embodiments is limited.

LIST OF REFERENCE NUMBERS

#

Number of diagnostic information

ADD

Network address of a field device

B

Description of a diagnostic information

BB

faceplate

D1

bus

DAT

time stamp

F1, F2, F3, F4

field device

FB

fieldbus

FB498

function module

GF

Total message window

gBSD

Device description file collection

ID

Identification of the field device

INFO

diagnostic information

LOG

logfile

SCADA

visualization environment

SPS

control unit

DAY

Day of field device

WS1, WS2

Workstation PC

Claims (16)

Method for determining diagnostic information (INFO) of at least one field device (F1, F2, F3, F4) of process automation, comprising: - receiving a diagnostic message of the field device (F1, F2, F3, F4); - reading a diagnostic data record of the field device (F1, F2, F3, F4); - storing the diagnostic data record in a field device (F1, F2, F3, F4) associated data block; - generating an image of the data block in a visualization environment (SCADA); Determining at least one diagnosis information (INFO) corresponding to the diagnostic data record by matching data contained in the image of the data module with a device description data file (GBSD), the device description data collection file (GBSD) containing all diagnostic information (INFO) that can be assigned to the field device (F1, F2, F3, F4). contains; and - visualization of the determined diagnostic information (INFO). Method according to Claim 1 , wherein the determined diagnostic information (INFO) is stored in a log file (LOG). Method according to Claim 2 , wherein the determined diagnostic information (INFO) a time stamp (DAT) and / or network relevant information of the field device (F1, F2, F3, F4), in particular its identification (ID) and / or its network address (ADD), assigned and in the log file (LOG) is saved. Method according to at least one of Claims 2 or 3 in which the determined diagnostic information (INFO) is stored in an XML format or in a text format. Method according to at least one of Claims 2 to 4 , wherein the log file (LOG) components of the control system (WS1, WS2, PLC) of a process plant, in which the field device (F1, F2, F3, F4) is integrated, is provided. Method according to at least one of the preceding claims, wherein device descriptions of a plurality of field devices (F1, F2, F3, F4) are summarized in advance and stored in the device description collection file (GBSD). System for determining diagnostic data of at least one field device (F1, F2, F3, F4) of the process automation, comprising: - a control unit (PLC) which communicates with the respective field device (F1, F2, F3, F4), wherein the Control unit (PLC) receives a diagnostic message of the respective field device (F1, F2, F3, F4) via the cyclic data traffic of the communication link, wherein the control unit is configured such a diagnostic data record of the respective field device (F1, F2, F3, F4), which device-specific Contains diagnostic information (INFO), to read out and to store this diagnostic data record in a data block belonging to the respective field device (F1, F2, F3, F4); and - a process visualization system (SCADA) running on a computer unit, in particular WinCC, wherein the process visualization system (SCADA) is designed to determine a diagnostic information (INFO) corresponding to the diagnostic data record by matching data contained in the image of the data module with a device description collection file (GBSD) and to visualize the determined diagnostic information (INFO), the device description collection file (GBSD) contains all the diagnostic information (INFO) that can be assigned to the respective field device (F1, F2, F3, F4). System after Claim 7 , wherein the field device (F1, F2, F3, F4) is designed as a Profibus DP slave and communicating with the control unit (PLC) via a Profibus DP fieldbus. System after Claim 7 , wherein the at least one field device (F1, F2, F3, F4) is a Profibus PA slave and communicatively connected via a Profibus PA fieldbus to a transparent coupling module or a non-transparent coupling module, wherein the Profibus DP link via a Profibus DP fieldbus with the control unit (PLC) in the communication environment. System according to at least one of Claims 7 to 9 , wherein the process visualization system (SCADA) is configured to store the determined diagnostic information (INFO) of the respective field device (F1, F2, F3, F4) in addition to the visualization in a log file (LOG). Function block (FB498) for use in a system according to one of Claims 7 to 10 , wherein the function block (FB498) in the control unit (PLC) is executable and wherein the function block (FB498) causes the reading out of the diagnostic data record and storing the diagnostic data record in the data block. Function block (FB498) to Claim 11 , where the function block (FB498) is a STEP7-compatible function block. Faceplate (BB) for use in a system according to any one of Claims 7 to 10 , wherein the faceplate (BB) associated with the respective field device (F1, F2, F3, F4), in the process visualization system (SCADA) implemented, and for visualizing the determined diagnostic information (INFO) is configured. Faceplate BB to Claim 13 , wherein the faceplate (BB) is a WinCC-compatible faceplate (BB). Faceplate (BB) according to at least one of Claims 13 or 14 , wherein in addition to the determined diagnostic information (INFO) the identification (ID) of the respective field device (F1, F2, F3, F4), the tag (TAG) of the respective field device (F1, F2, F3, F4) the network address (ADD) the field device (F1, F2, F3, F4), the network address of the master of the field device and / or the description (B) of the diagnostic information (INFO), in particular NE107-compliant visualized. Total reporting window (GF) for use in a system Claim 10 , where the total reporting window (GF) reads the diagnostic information (INFO) of all field devices from the log file (LOG) and visualizes the last 50 diagnostic information (INFO), in addition to the diagnostic information (INFO) the number (#) of the respective diagnostic information (INFO ), a time stamp (DAT) of the respective diagnostic information (INFO), the identification (ID) of the respective field device (F1, F2, F3, F4), the tag (TAG) of the respective field device (F1, F2, F3, F4) and / or the network address (ADD) of the respective field device (F1, F2, F3, F4) is visualized.

Images