FI20187116A1 - Parametrizable IO module - Google Patents
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0423—Input/output
- G05B19/0425—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0428—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F13/00—Interconnection of, or transfer of information or other signals between, memories, input/output devices or central processing units
- G06F13/10—Program control for peripheral devices
- G06F13/12—Program control for peripheral devices using hardware independent of the central processor, e.g. channel or peripheral processor
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
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- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/01—Protocols
- H04L67/12—Protocols specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
An IO module (401) for an automation system, the IO module (401) comprising a microprocessor (406) configured to communicate with IO channel modules and an IO bus switch where the microprocessor is configured to run parametrizable logic, wherein an output (1602) is controllable to a certain state when one input or a combination of inputs (1601) change to a predefined state.
Description
Field
The invention relates to IO modules in an automation system with process automation industry.
Background
In a process plant an automation system controls various quantities such as pressure, temperature, flow rate and levels. The automation system gets measurements from different probes and sets control values for different field devices. All these are connected together using different networking components. Typically, the automation system of large industrial facilities is built with hierarchical model. This hierarchy is described in ISA-95 standard. The automation system manages the operations in levels 0-2. The level 1 comprises of the actual process devices that fare sensors and actuator. These are connected with different device networks to IO modules. The modules are managed by IO substations which operate by the commands coming from controllers. The controllers run the automation applications that are designed for the process.
There are different kinds of field devices and a lot of different connection possibilities for them. Traditionally the field devices have been connected with standard 4-20mA signal, but new bus networks and Ethernet based networks have emerged. Different networks require different cabling and different connectors. The IO modules must be designed so that they can match these different networks. This requires a lot of different IO modules and flexible IO substation to carry the modules.
One typical issue with the process automation system is the slow default control cycle. In process industry 500ms control cycle has been a norm. During this process cycle the measurement device has provided information 30 through an IO module to the process controller and the process controller has
20187116 prh 07-09- 2018 commanded an IO module to activate an actuator for change. However, there are many applications that require faster process cycles than 500ms. These applications may relate to safety, machine condition or other topics. With these topics there are typically moving objects that must be stop before anything 5 critical happens. Time limits for such issues are typically in the scale of milliseconds to tens of milliseconds. Typically, these fast control actions are done with separate 10 structures with configurable local control. Safety control systems are good example of these.
There have been also faster process control cycles down to tens of 10 milliseconds, but since there are much higher device and cost requirement related, the faster cycles are mostly avoided.
All the aforementioned problems together make a great need for solution that solves high level control 10 and local fast control needs.
Brief description
The present invention seeks to provide a parametrizable 10 module as described in claim 1 and arrangement as described in claim 5. Additionally, the present invention describes method as described in claim 8.
List of drawings
Example embodiments of the present invention are described below, by way of example only, with reference to the accompanying drawings, in which
Figure 1 shows an overview of an automation system;
Figure 2 shows modular approach of controller groups; and
Figure 3 shows modular approach of 10 unit; and
Figure 4 shows the software architecture model; and
20187116 prh 07-09- 2018
Figure 5 shows the allocation of software functions; and
Figure 6 shows logic execution by 10 subsystem; and
Figure 7 shows one preferred embodiment; and
Figure 8 shows another preferred embodiment; and
Figure 9 shows another preferred embodiment; and
Figure 10 shows another preferred embodiment.
Description of embodiments
Figure 1 is an overall view of prior-art modern automation system. The automation system comprises of field devices 1 and 10 systems 2 that are connected via cabling into controllers 6. The cabling can be direct cabling 3, hub20 spoke type of network 4 or ring network 5. The controllers are connected to system bus 7, that can be redundant. Operator stations 8, history databases 9 and configuration servers 10 can be attached to the same network. A firewall 11 can be used to protect the system bus from other networks 12. Maintenance, ERP, configuration and simulation servers 13 can be in these networks. Additional 25 firewall 14 can be used for connection to further networks 15.
Figure 2 describes modular Controller group 104 and modular 10 units 301. Controller group is equipped with integrated network switch module 302 that can be single or redundant. Other modules comprise Controller modules 303 and interface modules 304. The benefit of this approach is that the amount of 30 Controller modules is not tied with number of interface modules and the amount can be adapted to actual needs case by case. Each interface module contains
20187116 prh 07-09- 2018 interfaces for IO poles 101, standard field buses 305, e.g. PROF1BUS or serial interfaces, e.g. RS-232, RS-485. By introducing more interface modules to Controller group, the more 10 poles or field buses can be controlled. 10 poles contain 10 units which contain single 10 channel modules. 10 unit can be basic 10 5 units, 10 units complying functional safety, ATEX compliant units, machine condition monitoring (MCM) units or mains voltage tolerant 10 units. Benefit of this approach is that 10 channel amount, type and mix can be altered with minimum effort.
Figure 3 describes an embodiment of 10 unit on 10 pole. 10 unit 10 comprises 10 module 401, 10 channel modules 402 and 10 termination module 404. 10 termination module acts as base module for other modules. 10 module comprises a microprocessor 406 for communication with 10 channel modules and 10 bus switch 403 for Ethernet communication. 10 channel module comprises microprocessor for 10 control, fail safe functions, field loop 407 fault monitoring 15 and communication purposes to 10 module. 10 channel module comprises also function for indicating whether it has been taken into use i.e. configured or not. The communication purposes may be e.g. Highway Addressable Remote Transducer (HART) communication. Field equipment electrical control is performed by the 10 channel module. 10 units are connected to 10 bus 405 for 20 data exchange with Controller Interface modules. In order to enable possibility to replace or change 10 module online, the 10 bus switch is separated from 10 module. Due module breaks on control systems, online changes are needed with minimum impact to other areas of the system. The 10 bus is Ethernet based communication. Any suitable protocol can be used on top of physical IEEE 802.3 25 infrastructure.
Figure 4 shows software model. Controller applications software functions are divided to multiple modular layers. Each layer can be allocated independently to automation platform and can be independently redundant. Controller 1211 functions include at least execution 30 logic 1203, related external connections 1202 and 10 connections 1201. External connections include functions such as data communication between other
20187116 prh 07-09- 2018 controllers, user interface connections and connections to history services. IO connections include connection IO interface data. IO connections are purely name based to allow late IO allocation and flexible changes of IO channel types. It is typical that IO type of connection may change from wired IO to link IO e.g.
MODBUS IO from PLC or vice versa. IO interface 1212 is standardized way to connect to any IO. It provides name based data interface to IO, standard field buses e.g. PROFIBUS, PROFINET or links e.g. MODBUS interfaces. IO interface has IO specific logic 1204 including IO channel or IO bus parametrization, data interface to IO modules 1205 or to field buses and fail-safe logic if connection to 10 controller is lost and some fail safe actions are required e.g. close valves, stop motors. IO module 1213 manages set of IO channel modules 1214. It manages IO channel connections 1207 from IO interfaces to IO modules read/write process data and read diagnostics data. IO channel logic 1206 normalizes IO data if not done by IO channel module and may have additional parametrizable logic. IO 15 channel module 1214 handles IO signal conditioning logic 1208. This logic contains e.g. conversion of analog input AD-converter 0-20mA measurement to standardized IO data e.g. value 0-65536. IO channel module typically handles calibration data related to analog measurements or outputs. Field connections 1209 connect IO channel module measurement and output signals to field sensors 20 and actuators
Figure 5 shows allocation options of software functions. Typical rule is that when IO size i.e. number of IO behind one controller, grows, centralized solution with high capacity platform for controller and IO interface is costeffective solution when calculating cost per IO channel. This solution has 25 drawback that in failure cases affected process area is larger due to higher number of affected IO channels. When IO size is smaller it is more feasible to allocate control and IO functions closer to IO channels. Distributed control function allocation enables partial testing of system. It is typical that in control application development, work is distributed to teams located in wide area. If 30 application involves specific equipment, testing can be done with laptop and one IO module with embedded controller and IO interface functionality. In cabinet
20187116 prh 07-09- 2018 manufacturing allocation of controller and IO interface to IO poles enables testing of field connection without installing separate controller group. Separate controller 502 and IO interface 202 in controller group provide best consistent control capacity. IO interface is connected to 10 pole via IO pole connector 1301 5 and IO bus connects to IO units 301. Controller function and IO interface function have dedicated hardware.
When IO interface hardware has sufficient capacity to run control E and IO interface F functions these both functions G can be run inside IO interface hardware. If control function is secondary e.g. lighting control or air ventilation 10 control functionality can be reasonably run in virtualization platform 107. Virtual controller I and virtual IO interface J provide combined control functionality H. When IO size is small e.g. remote IO or in manufacturing controller and IO interface functionality can be located to IO pole 1301 connector including Ethernet switch and microprocessor. Combined functionality marked as K. In 15 minimal case controller and IO interface functionality can be allocated to IO module L. Allocating functionality near IO channels is also key to fastest IO loops. This minimizes communication delays between IO channel and controller functionality.
Figure 6 describes logic execution by IO subsystem. The 10 module 20 401 may include microprocessor 406 that is capable of running some or all parts of the controller 502 code. If the microprocessor is powerful enough the IO module may run all of the application needed by it to accomplish the needed automation task. There are two benefits from this approach. One is that the actual controller is not needed. This kind of solution is very beneficial for very small 25 automation installations due to reduced space needed. At the same time the reliability increases since the critical communication paths to controller are not needed. Another benefit is that the IO module can run faster applications due to the reduced need of communication time.
If the microprocessor 406 is not powerful, it can manage only light 30 tasks and cannot run the whole application. In these cases, the microprocessor may run protective logics or simple control logics. In most cases the
20187116 prh 07-09- 2018 parametrizable logic is very simple: output 1602 must be controlled to certain state when one input or combination inputs 1601 change predefined state. The inputs are directly accessible 1603 by the microprocessor 406. 10 module can execute such logic very fast, because inputs are scanned continuously. One can 5 add parameters to logic to indicate which input changes need to be monitored and how these changes should control the outputs. As 10 module runs this simple logic, reaction to change of input can be very fast.
The 10 module that provides this functionality is called parametrizable 10 module. This kind of device is highly beneficial. One physical 10 module with 10 common connections can manage both; slow higher-level process automation and local parametrizable fast actions. The normal control operation from remote controllers is maintained as such, but additional fast control or safety procedures are provided locally.
Using parametrizable 10 module removes the need of having more 15 computing capacity in the 10 modules or enables having less 10 modules to run same tasks. Simultaneously the need of faster buses is reduced. Additional benefit is the independence of the local 10 operation. If any malfunction occurs to the communication lines between the parametrizable IO module and the controllers the required fast control action is not affected.
The configuration of parametrizable 10 module is done through automation system configuration software. The software provides user interface for configuring the parameters of 10 module. There are different simple logic operators that can be used to configure the parametrizable 10 module. Typical logic operators are such as, but not limited to: AND, OR, NOT, value comparisons, 25 counters and value holders. Additionally, some arithmetic operators can be used.
The values from local parametrized operators can be forwarded to the controllers and further processed there.
One example of preferred use for parametrizable 10 module for 30 controlling motorized valve is shown in Fig 7. There can be enormous power turning the valve and if the valve is closed and the same turning power is applied,
20187116 prh 07-09- 2018 defects are very probable. The parameterized 10 module can be used to safeguard the motor by using same signals that are normally used for measurement and control by upper level controllers 502. No additional devices or cabling is needed. The controller can provide commands such as “close” 1708 - “open” 1709 5 “brake” 1710. The 10 module forwards these commands to outputs 1705, 1706, 1707 only if related sensors are in correct state. E.g. when the controller commands “close” the IO module checks if the signals “Limit close” 1701 and “Torque, close” 1702 are not active. If either of those is active during the movement, the 10 module immediately ceases the movement. This happens 10 before the controller reacts to the “Limit close” 1712 or “Torque, close” 1713 signals. In the next control cycle the controller acts accordingly. However, the parametrizable 10 module has already managed the critical situation. Similar procedure can also be parametrized to “open command with “limit open” 1703 and “torque, open” 1704 signals.
Another example of preferred use for parametrizable 10 module for controlling valve is shown in Fig 8. There can be cases where stopping the filling of some tank must be done in all circumstances. With such cases all additional steps that are unneeded must be avoided. Using parametrizable 10 module with 20 input information about level 1801 of the tank that is normally provided as input 1804 to the controller can be used to stop the filling of the tank when parametrized value is reached even if the level signal never reaches the controller. In normal operation the controller can be used to directly command the output 1803 to control the valve with the same 10 1802.
Another example of preferred use for parametrizable 10 module for controlling blade is shown in Fig 9. The flowing pulp web traverses fast (1-5 m/s). Cutting the pulp to be baled must be done in very strict timeframe to provide accurate sized pulp sheets. The normal process control cycle time is far too slow 30 for this kind of operation. Adding a digital input with the information about pulp web edge 1901 the 10 subsystem can detect 1906 the edge and use accurate
20187116 prh 07-09- 2018 parametrized counter timer 1904 to calculate the output 1902 of blade control. However, the digital input 1903 from the process controller mandates whether it activates the blade or not. This way fast parts of the process can be controlled with the same 10 devices as slower parts. The input signal 1901can also be held 5 1711 stable for data input 1905 for the controller.
Another example of preferred use for parametrizable 10 module for machine condition monitoring is shown in Fig 10.
In machine condition monitoring applications fast signals, like signals 10 from vibration sensors are used as inputs and characteristic values are calculated from input signal and these values may be used in control logic to safeguard the machine. When sufficient microprocessor is used in parametrizable 10 module, such characteristic values can be calculated in the 10 module and use these values as part of safeguarding logic executed in the 10 module.
There can be upper level machine condition monitoring application to follow long term condition of filed devices. This application is typically run on separate computer or dedicated controller connected to automation system 10 bus. The upper level long term condition monitoring tries to reveal malfunctions that are detectable by trends. However, the same signals, like signals from 20 vibration sensors that are used for long term monitoring can also be used for revealing immediate malfunction of devices. The revealing issue can be for example a high sporadic vibration. This can be detected by calculating 1913 some characteristic from incoming signal 1910. This calculation may provide peak values, root mean square (RMS) 1914 or other similar value. The parameters 25 needed for the calculation, such as time span, may be parametrized. These calculated values can be compared to parametrizable limit values that mandate the logic to stop the device. The output 1911 of the logic overcome the actual command 1915 from the controller. This kind of safeguarding logic bring additional benefits by shutting down critically malfunctioning devices by stopping 30 the motors running them and possibly releasing some brake functionality as soon as possible and thus avoiding further defects.
Additionally, the parametrizable 10 module can be used to provide fast human input to the subsystem. This kind of input lags too much if normal 500ms control cycle is used to react to human pressing of control buttons. This can be 5 e.g. control of the paper web cutter where the human input must be reacted rapidly. Using parametrizable IO module enables controlling common actuator by direct human input and control system input.
Claims (13)
1. An IO module (401) for an automation system, the IO module comprising a microprocessor (406) configured to communicate with IO channel modules (402) and an IO bus switch (403) characterized in that the microprocessor is configured to run parametrizable logic, wherein an output (1602) is controllable to a certain state when one input or a combination of inputs (1601) change to a predefined state.
2. The IO module (401) of claim 1, wherein the IO module is configured to run a machine condition monitoring application.
3. The IO module (401) of claim 1 or 2, wherein the IO module is configured to calculate characteristics values on the basis of input signals (1910) from vibration sensors and use the characteristic values to safeguard a machine.
4. The IO module (401) of any preceding claim, wherein the IO module is configured to simultaneously transmit at least some of the input data (1601) to controller (502) and receive control commands (1605) from controller.
5. An arrangement for fast control of critical task with automation system IO module (401) having a microprocessor (406), characterized by that the microprocessor is configured to run parametrized logic and the IO module is part of IO unit (301) that comprise also of single IO channel modules (402) and IO termination module (404) that acts as base module for other modules and where the IO module is connected via Ethernet network with at least one controller (502) that can receive input data from IO module and/or transmit commands to IO module.
6. The arrangement as claimed in 5, where there are vibration sensors connected to IO channel modules (402) providing input signal (1910) to the IO module (401) and output (1911) to motor or brake.
20187116 prh 07-09- 2018
7. The arrangement as claimed in 5, where there are at least one limit switch and/or torque sensor providing input signal (1801) through channel module (402) to the 10 module (401) and output (1802) to motor or brake.
8. A method for controlling fast actions with automation system 10 module (401) characterized by that the method comprising:
- scanning the state of one or more inputs (1601)
- providing (1604) the input data to controller (502)
- changing the state of outputs (1602) according to parametrized logic running in the microprocessor (406)
- while receiving control inputs (1605) from controller (502)
9. The method as claimed in 8, where the parametrized logic can run operators comprising AND, OR, NOT, arithmetic operators, value comparisons and counters to manipulate the input data values.
10. The method as claimed in 8, where the parametrized logic is configured to run a machine condition monitoring application.
11. The method as claimed in 8, where the parametrized logic is configured to run valve shield by preventing operating the valve if signals from limit switches or torque sensors are triggered.
12. The method as claimed in 8, where the parametrized logic is configured to run independent tank filling stopper when parametrized level of the tank is reached.
13. The method as claimed in 8, where the parametrized logic is configured to run pulp web cutter with input signal providing the information about present pulp web edge and parametrized timer to control the blade.
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