CN100555136C - Unusual condition prevention method and system in the processing factory - Google Patents
Unusual condition prevention method and system in the processing factory Download PDFInfo
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- CN100555136C CN100555136C CNB2005800068427A CN200580006842A CN100555136C CN 100555136 C CN100555136 C CN 100555136C CN B2005800068427 A CNB2005800068427 A CN B2005800068427A CN 200580006842 A CN200580006842 A CN 200580006842A CN 100555136 C CN100555136 C CN 100555136C
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Abstract
A kind of system that detects the unusual condition relevant with processing factory.This system receives the signal Processing data of the signal Processing data collection module generation that is realized by a plurality of equipment.Described signal Processing data collection module can produce the data such as statistics, frequency analysis data, autoregression data, wavelet data.This system comprises that the Allocation Analysis machine is to detect at least one unusual condition relevant with processing factory.These signal Processing data offer analytical engine, and whether the analytical engine decision should take measures.
Description
The cross reference of related application
The application requires to submit to, be entitled as on March 3rd, 2004 the U.S. Provisional Patent Application No.60/549 of " the unusual condition prevention in the processing factory ", and 796 right, its whole disclosures are incorporated among the application in full to be used as various purposes.
The application also relates to following patented claim:
Application No.: _ _ _ _ _ _ _ _, (agency's number of putting on record No.30203/39746), itself and the application submit, are entitled as " configuration-system and the method that are used for the unusual condition prevention of processing factory " on the same day to;
Application No.: _ _ _ _ _ _ _ _, (agency's number of putting on record No.30203/40056), itself and the application submit, are entitled as " being used for the data presentation system at processing factory's abnormal situation prevention " on the same day to.
Whole disclosures of above referenced patented claim be incorporated in full the application please in as various purposes.
Technical field
The execution that present invention relates in general in the processing factory diagnosis and safeguard is specifically related to provide in the mode that reduces or prevent the unusual condition in the processing factory predetective diagnosis ability of processing factory.
Background technology
Process Control System, the Process Control System that for example is used for chemistry, oil or other process, generally include one or more centralized or distributed process controller, these process controllers are by simulation, numeral or analog/digital hybrid bus, communicate to connect at least one main frame or operator workstation and one or more process control and instrument and equipment, for example field apparatus etc.Field apparatus can be that for example valve, valve positioner, switch, transmitter and sensor be (for example, temperature, pressure and flow sensor), they are arranged in the process plant environments and carry out various functions during the course, for example open or close valve, measurement process parameters, increase or reduce that fluid flows etc.Smart devices for example meets known FOUNDATION
TMFieldbus (hereinafter being called Fieldbus) agreement or
The field apparatus of agreement, other control function that can also carry out control calculating, alarm function and in process controller, realize usually.
Usually be arranged at the process controller in the process plant environments, receive that expression is produced by field apparatus or the signal of process measurement relevant or process variable and/or belong to the out of Memory of field apparatus with field apparatus, and the implementation controller application program.For instance, this controller application program realizes different control modules, these control modules are carried out the process control decision-making, are produced control signal according to the information that receives, and with the field apparatus such as HART and Fieldbus field apparatus in control module or piece (block) co-ordination carried out.Control module in the process controller sends control signals to field apparatus by communication line or signal path, thus the operation of control procedure.
Information from field apparatus and process controller can be used for one or more other hardware devices usually, operator workstation for example, the maintenance work station, personal computer, portable set, the data history records device, the report generator, integrated data store etc., so that operator or maintainer can carry out the required function relevant with process, for example change the setting of process control block (PCB), the operation of control module in modification process controller or the smart devices, the current state of particular device in view procedure or the processing factory, check the alarm that produces by field apparatus and process controller, the operation of simulation process is with start-up or test process Control Software, problem in the diagnosis processing factory or hardware fault etc.
A typical processing factory has many process control and the measuring equipment that is connected to one or more process controllers, for example valve, transmitter, sensor etc. the time, also has many other utility appliance essential or relevant for process operation.These optional equipments comprise, for example power-supply device, generating and controller switching equipment, the rotating machinery such as turbine, motor etc., and they are arranged at a plurality of places of a typical plant.Though these optional equipments do not need to produce or the use variable, and in many cases, even can not be subjected to process controller control to be free of attachment to process controller for the influence process operation, but for the proper handling of process, these equipment still unimportant and also finally be essential.
Known, problem often appears in the process plant environments, particularly appears in the processing factory with a large amount of field apparatuss and utility appliance.These problems can show as and make equipment, logical block fault or malfunctioning, for example are in the one or more faults of communication between devices in the software program of improper pattern, the process control loop of having carried out inappropriate adjustment, the processing factory etc.Though it is multiple that in fact these or other problem have, they cause process in relevant with the suboptimum performance of processing factory usually abnormality operation (that is, processing factory is in unusual condition) usually.Developed many diagnostic tools and application program, so that the reason of the problem in detection and the definite processing factory, and when problem has taken place and has been detected, help operator or maintainer diagnosis and correct these problems.For example, usually be connected to the operator workstation of process controller by communicating to connect such as direct or wireless bus, Ethernet, modulator-demodular unit, telephone wire, have the processor and the storer that are suitable for operating software or firmware, for example the Delta that sells by Emerson process management
TMWith the Ovation control system, these systems comprise numerous control modules and control loop diagnostic tool.Similarly, can by identical with the controller application program communicate to connect or by be connected with embedded technology (OPC) such as the object linking that is used for process control, different communication the portable connection is connected to the maintenance work station such as the process control equipment of field apparatus, generally include one or more application programs, these application programming are to check by what the field apparatus in the processing factory produced to safeguard alarm and caution, with the equipment in the test processing factory and carry out maintenance activity to field apparatus in the processing factory and miscellaneous equipment.Developed similar diagnosis of application program, with the problem of utility appliance in the diagnosis processing factory.
Therefore, for example asset management solution (AMS) application program of being sold by Emerson process management (is disclosed in the United States Patent (USP) NO.5 that is entitled as " being used in the integrated communicaton network in the field apparatus management system " to small part, 960, in 214), can belong to the data of field apparatus to determine and to follow the tracks of the operation of field apparatus with field device communicating and storage.In some example, the AMS application program can be used for field device communicating to change the parameter of this field apparatus, thereby the application program that makes this field apparatus operation self, for example self calibration program or self-diagnostic program are to obtain about the state of this field apparatus or to perfect the information of degree (health).This information can comprise, for example status information (for example, whether alarm or other similar incident take place), device configuration information (for example, the type of mode that the current mode of field apparatus maybe can be configured and the measuring unit that uses by this field apparatus), device parameter (for example, field apparatus value range and other parameter) etc.Certainly, these information can use with monitoring by the maintainer, safeguard, with and/or the diagnosis field apparatus in problem.
Similarly, many processing factories comprise monitoring of tools and diagnosis of application program, the RBM product (ware) that provides by the CSI system for example, or be used to any other known application program of monitoring, diagnose and optimizing the mode of operation of various rotating machinerys.The maintainer uses these application programs to safeguard and to check the performance of the rotating machinery in the factory usually, and with the problem of definite rotating machinery, and when and whether definite rotating machinery must be repaired or be replaced.Similarly, many processing factories comprise electric power control and diagnosis of application program, and for example the application program that is provided by Liebert and ASCO company is generated electricity and controller switching equipment with control and maintenance.Known ground, operation Control and Optimization application program in processing factory, real-time optimization device (RTO+) for example is to optimize the control activity of processing factory.Such optimization application is used the model of complicated algorithm and/or processing factory usually, predict how to change that input optimizes processing factory with for example relevant operation of profit of some variable that need optimize.
In one or more operator workstations or maintenance work station, these and other diagnosis and optimization application are that realize on the basis with general system (system-wide) usually, and can provide pre-configured demonstration to operator workstation or maintenance work station according to the mode of operation of equipment in processing factory or the processing factory and device.The typical demonstration comprises: alarm shows that it receives the alarm that is produced by process controller in the processing factory or miscellaneous equipment; Control shows, the process controller in its expression processing factory and the mode of operation of miscellaneous equipment; Safeguard to show the mode of operation of each equipment etc. in its expression processing factory.Similarly, these and other diagnosis of application program can make operator or maintainer readjust control loop or reset other controlled variable, so that one or more field apparatus operations are tested, determine the current state of these field apparatuss, thereby calibrate field devices or other device, or execution is to the detection and the correction activity of the other problem of each equipment and device in the processing factory.
Though various application programs and instrument are very helpful to the problem in identification and the correction processing factory, but these diagnosis of application program are configured to just use after problem has appeared in the processing factory usually, therefore are exactly after unusual condition is Already in the processing factory.Lamentedly, before using these tool detection, identification and correcting unusual condition, may just there be a period of time in unusual condition, and this causes, and processing factory's performance is a suboptimum in time period of, identification detected in problem and correction process.In many cases, according to alarm, caution or processing factory best performance not, control operation person can at first detect and have some problems.Potential problems can be notified to the maintainer after this operator.This maintainer may detect also and may detect less than real problem, and may further point out (prompt) before real operation test or other diagnosis of application program, or carries out other required activity of these real problems of identification.In case the problem of identifying, the maintainer may need to determine parts and plan that portion safeguards flow process, all these all can cause obtaining occurring between the correction a tangible time period in a problem appearance and this problem, in this time period, processing factory operates in usually and operates under the relevant unusual condition with the suboptimum of factory.
In addition, many processing factories can experience a kind of great cost of processing factory's appearance in the short relatively time or unusual condition of infringement of causing.For example, if there is some unusual condition, even if there is very short time in they so, these unusual conditions also can bring the unexpected great shut-down period in the extensive damage to equipment, raw-material loss or the processing factory.Therefore, detection problem after only problem has occurred in processing factory no matter problem corrects to such an extent that how soon have, all may cause heavy losses or infringement in the processing factory.Therefore, ideal situation is to prevent the unusual condition appearance at first as possible, rather than the problem in do the best after unusual condition occurs simply reaction and the correction processing factory.
At present, have a kind of technology that can be used for image data, this technology can make the user before the real appearance of unusual condition, some unusual condition that prediction takes place in processing factory, thereby the unusual condition of taking measures to be predicted to prevent appears in processing factory before any heavy losses.This flow process is disclosed in the u.s. patent application serial number No.09/972 that is entitled as " root cause diagnostics ", 078 (partly based on U.S. Patent application NO.08/623,569, existing U.S. Patent No. 6,017,143) in.Whole disclosures of these two applications are herein incorporated for reference.Usually, this technology for example in each of field apparatus, is provided with statistical data collection and processing module or statistical treatment monitoring (SPM) module at many equipment of processing factory.For example, statistical data collection and processing module gatherer process variable data, and determine some and the relevant statistical measures of data of gathering, for example mean value, intermediate value, standard deviation etc.These statistical measures can send to the user subsequently, and analyzedly are used to hint the imminent pattern of known exception situation (pattern) with identification.If detect a specific suspicious unusual condition that will take place, then at first take measures correcting potential problem, thereby avoid unusual condition.But for typical maintainer, it may be consuming time and dull gathering and analyze data, especially in the processing factory with the field apparatus that is used for gathering statistics in a large number.And further, when a maintainer can gather statistics, this maintainer may not know how to go to analyze best or check data, or determined which imminent unusual condition is these data all hinted, if any.
And usually, configuration factory is to collect and to check that the whole statistic processes data that produced by each SPM are to bother very much with dull, especially in large-scale processing factory.In fact, at present the user usually must establishment monitors the OPC client of interested each parameter in the different field apparatuss respectively, this means that each field apparatus all must be configured to gather these data respectively.This layoutprocedure is very consuming time and be vulnerable to the infringement of mistake.
Summary of the invention
Be a kind of system that detects the unusual condition relevant on the one hand with processing factory.This system receives the signal Processing data of the signal Processing data collection module generation that is realized by a plurality of equipment.This signal Processing data collection module can produce the data such as statistics, frequency analysis data, autoregression data, wavelet data.This system comprises that the Allocation Analysis machine is to detect at least one unusual condition relevant with processing factory.These signal Processing data offer analytical engine, and whether the analytical engine decision should take measures.
Be a kind of system that the Allocation Analysis machine detects the unusual condition relevant with processing factory that is used on the other hand, comprise being used to specify the user interface mechanism for the treatment of by the signal processing parameter of analytical engine analysis.These signal processing parameters can be produced by the signal Processing data collection module that a plurality of equipment in the processing factory are realized.Another user interface mechanism can be used to specify the analysis to the signal specific processing parameter.Configuration data receives and stores by user interface mechanism.
Description of drawings
Fig. 1 is the example block diagram of a processing factory, and this processing factory has distributed control and maintaining network, and wherein this network comprises one or more operator and maintenance work station, controller, field apparatus and utility appliance;
Fig. 2 is the example block diagram of a part of the processing factory of Fig. 1, and its communication that shows between each element of the unusual condition prevention system in the different parts of processing factory is interconnected;
Fig. 3 is the demonstration of the configuration of one group of statistic processes monitoring module in a kind of equipment of the processing factory of Fig. 1 or Fig. 2;
Fig. 4 is the statistic processes acquisition module in the allocation processing plant and gathers the process flow diagram of the technology of statisticss in operating period of processing factory from these modules;
Fig. 5 is a width of cloth display screen figure, and it shows the plant hierarchy (hierarchy) that opc server is gathered in the processing factory of Fig. 1 or Fig. 2;
Fig. 6 is a width of cloth display screen figure, and it shows the hierarchy of the plant components relevant with the equipment with statistic processes monitoring module;
Fig. 7 is a width of cloth display screen figure, and it makes the user can be chosen in one group of statistic processes monitoring parameter to be monitored in the statistic processes monitoring module;
Fig. 8 is a width of cloth display screen figure, and it can be provided to be illustrated in the collection statistic processes monitor data that produces in the equipment with statistic processes monitoring module;
Fig. 9 is a width of cloth display screen figure, and it shows the browser hierarchy, and this hierarchy comprises the statistics element of data collecting module collected in the slave unit;
Figure 10 is a width of cloth display screen figure, and it shows increases in the equipment at the scene or the mode of configuration statistical data collection module;
Figure 11 is a width of cloth display screen figure, and it shows the user and can handle to check the mode of trend data;
Figure 12 is a width of cloth display screen figure, and it shows the user and can handle to check the mode of the raw data of being gathered from the statistics gatherer module;
Figure 13 is a width of cloth display screen figure, and it shows the curve map of statistic processes monitoring parameter to the time;
Figure 14 is a width of cloth display screen figure, and it shows one group of different statistic processes monitor data to four curves of time, and wherein each all has the one or more parameters of describing on same curve;
Figure 15 is a width of cloth display screen figure, and the histogram that it shows the statistic processes monitoring parameter comprises control limit and regulation boundary;
Figure 16 is a width of cloth display screen figure, shows the X control chart of statistic processes monitor data to the time;
Figure 17 is a width of cloth display screen figure, shows the S control chart of statistic processes monitor data to the time;
Figure 18 is a width of cloth display screen figure, shows the two-dimentional scatter diagram of one group of statistic processes monitoring parameter;
Figure 19 is a width of cloth display screen figure, shows the three-dimensional scatter diagram of one group of three statistic processes monitoring parameter;
Figure 20 is a width of cloth display screen figure, shows the four-dimensional scatter diagram of one group of four statistic processes monitoring parameter;
Figure 21 is a width of cloth display screen figure, shows the correlation matrix of one group of statistic processes monitoring parameter;
Figure 22 is a width of cloth display screen figure, shows the three-dimensional bar chart of the part of the correlation matrix of describing Figure 21;
Figure 23 is a width of cloth display screen figure, shows expression and the domain of dependence curve of expecting domain of dependence deviation;
Figure 24 is a width of cloth display screen figure, shows a colour coding correlation matrix;
Figure 25 is a width of cloth display screen figure, and the comparison chart that compares between two kinds of measured values that provide the process variable of selected equipment is provided, and makes the user can check other user interface component relatively;
Figure 26 is a width of cloth display screen figure, shows two statistics monitor procedure parameters to the curve of time, has shown known correlativity between these parameters;
Figure 27 is a width of cloth display screen figure, shows the curve of a correlation to the time;
Figure 28 is a width of cloth display screen figure, shows the curve of a plurality of correlations to the time;
Figure 29 is a width of cloth display screen figure, shows a correlation and reference value curve to the time;
Figure 30 is a width of cloth display screen figure, shows the associated change matrix for one group of statistic processes monitoring parameter;
Figure 31 is a width of cloth display screen figure, shows a colour coding degree of correlation transformation matrices;
Figure 32 is a width of cloth display screen figure, shows the curve of a total correlation value to the time;
Figure 33 is a width of cloth display screen figure, shows a colour coding degree of correlation transformation matrices and the total correlation value curve to the time;
Figure 34 is a width of cloth correlation and corresponding to the polar plot at the angle of the slope of best-fit line;
Figure 35 is a width of cloth display screen figure, shows a plurality of correlations and corresponding to the polar plot at the angle of the slope of each best-fit line;
Figure 36 is a width of cloth display screen figure, shows a plurality of associated change values and corresponding to the polar plot at the angle of the slope of each best-fit line;
Figure 37 is the block scheme of exploitation of criterion machine and executive system, and this system can create the user and criterion is applied to from the statistic processes monitor data of processing factory's collection;
Figure 38 is a width of cloth display screen figure, shows one and makes the user can be the criterion machine exploitation of Figure 37 and the configuration screen of executive system establishment criterion;
Figure 39 is a width of cloth display screen figure, show criterion and carry out the machine operation summary, this high-level summary by the employed criterion of criterion machine of Figure 37 and the alarm that is produced by this criterion machine;
Figure 40 is a width of cloth display screen figure, shows to make the user can be the criterion machine exploitation of Figure 37 and second configuration screen of executive system establishment criterion;
Figure 41 is a width of cloth display screen figure, shows to make the user can be the 3rd configuration screen of the establishment criterion of exploitation of the criterion machine of Figure 37 and executive system;
Figure 42 is a width of cloth display screen figure, shows the part of processing factory, and this demonstration comprises warning/information warning;
Figure 43 is another width of cloth display screen figure, shows the part of processing factory, and this demonstration comprises warning/information warning;
Figure 44 is again a width of cloth display screen figure, shows the part of processing factory, and this demonstration comprises warning/information warning;
Figure 45 is another width of cloth display screen figure, shows the part of processing factory, and this demonstration comprises warning/information warning;
Figure 46 is the figure that is connected in another processing factory with the interfacing equipment of execute exception condition detection and prevention; And
Figure 47 is the figure that is connected in the another processing factory with the interfacing equipment of execute exception condition detection and prevention.
Embodiment
With reference to Fig. 1, exemplary processing factory 10 that therein can execute exception situation prevention system comprises by one or more communication networks and interconnected many controls of utility appliance and maintenance system.Especially, the processing factory 10 of Fig. 1 comprises one or more Process Control Systems 12 and 14.Process Control System 12 can be traditional Process Control System, for example PROVOX or RS3 system or any other control system, Process Control System 12 comprises operator interface 12A, this operator interface is connected to controller 12B and I/O (I/O) card 12C, this I/O (I/O) card is connected to various field apparatuss, for example analog field device can and highway addressable remote sensor (HART) field apparatus 15 successively.Can be the Process Control System 14 of distributed process control system, comprise one or more operator interface 14A, operator interface 14A be by bus, and for example industry ethernet is connected to one or more distributed director 14B.Controller 14B can be, for example the DeltaV that is sold by Emerson process management of Austin (Austin), Texas (Texas)
TMThe controller of controller or any other required type.Controller 14B is connected to one or more field apparatuss 16 by I/O equipment, for example Hart or Fieldbus field apparatus or any other intelligence or non intelligent field apparatus, it comprises, for example those uses
And
The equipment of agreement.As is known, field apparatus 16 can provide and process variable and the analog or digital information information-related with miscellaneous equipment to controller 14B.Operator interface 14A can store and carry out instrument available concerning this process control operator (tools), is used for control and comprises for example operation of the process of Control and Optimization device (optimizers), diagnostician, neural network, tuned circuit etc.
And further, maintenance system is for example carried out the monitoring of AMS application program or any miscellaneous equipment and the computing machine of communication application program, can be connected to Process Control System 12 and 14, or be connected to wherein each equipment, to carry out maintenance and monitor activities.For example, by the communication line or the network (comprising wireless or the portable set network) of any needs, maintenance calculations machine 18 can be connected to controller 12B and/or equipment 15, so that communicate by letter with equipment 15, and in some cases, other maintenance activity is reshuffled or carried out to equipment 15.Similarly, maintenance applications, AMS application program for example, can be installed among the one or more user interface 14A relevant with distributed process control system 14, and move by these user interfaces, safeguard and monitoring function that to carry out these functions comprise the data acquisition relevant with the operating conditions of equipment 16.
Processing factory 10 also comprises various rotating machinerys 20, for example turbine, motor etc., they by some nonvolatil or temporary communication links (for example, be connected to equipment 20 with read and after the bus, wireless communication system or the portable set that remove) be connected to maintenance calculations machine 22.Known monitoring and the diagnosis of application program 23 that is provided by for example CSI (Emerson process management company) can be stored and carry out to maintenance calculations machine 22, or other any known being used to application program of diagnosing, monitor and optimizing the mode of operation of rotating machinery 20.The maintainer uses application program 23 to safeguard and check the performance of rotating machinery 20 in the factory 10 usually, and with the problem of definite rotating machinery 20, and when and whether definite rotating machinery 20 must be repaired or be replaced.In some cases, outside consulting or the data that service organization can temporarily obtain or measurement and equipment 20 are relevant, and use these data that equipment 20 is analyzed, thus the detection problem, performance is not good or other influences the difficult problem of equipment 20.In these situations, the computing machine of operating analysis can not be connected to the remainder of system 10 by any communication line, maybe can be the remainder that temporarily is connected to system 10.
Similarly, have the generating relevant with processing factory 10 and the generating and the distribution system 24 of controller switching equipment 25, be connected to other computing machine 26 by for example bus, computing machine 26 operations are also checked generating and controller switching equipment 25 in the processing factory 10.Computing machine 26 can be carried out control of known electric power and diagnosis of application program 27, and those programs that provided by Liebert and ASCO or other company for example are with control with safeguard and generate electricity and controller switching equipment 25.And, in many cases, outside consultant or service organization can use the attendant application of the data relevant with equipment 25 of temporarily obtaining or measuring, and it is not good or influence other difficult problem of equipment 25 with detection problem, performance to use these data that equipment 25 is analyzed.In these situations, the computing machine of operating analysis (for example, computing machine 26) can not be connected to the remainder of system 10 by any communication line, maybe can be the remainder that temporarily is connected to system 10.
As shown in Figure 1, at least a portion of computer system 30 execute exception situation prevention systems 35, and especially, computer system 30 is stored and is carried out configuration and data collection application 38, can comprise checking or interfacing application programs 40 and exploitation of criterion machine and executive utility 40 of statistics gatherer and processing module, and extra storage statistical treatment monitor database 43, the statistics that produces in some equipment in statistical treatment monitor database 43 storing processs.Usually, configuration and data collection application 38 dispose and with many statistical data collection and analysis module (not shown in figure 1) in each communicate, these modules are arranged in any equipment that other needs of field apparatus 15,16, controller 12B, 14B, rotating machinery 20 or its secondary computer 22, generating set 25 or its secondary computer 26 and processing factory and device, thereby each from these modules is gathered statistics (or in some cases, and utilize these data to come execute exception situation prevention the gatherer process variable data).Configuration and data collection application 38 can communicate to connect each computing machine or equipment in the processing factory by hard wire bus 45, or alternately, can comprise for example wireless connections by any other communicating to connect of needing, use the special use of OPC to connect, for example rely on portable set to wait to communicate to connect with the batch (-type) connection of image data.Similarly, by LAN or public connection, for example Ethernet, phone connection etc. (Figure 1 shows that the Internet connect 46), application program 38 can obtain with processing factory 10 in the field apparatus data relevant with device, these data are by for example third party ISP collection.And, by various technology and/or agreement, comprising for example Ethernet, Modbus, HTML, XML, proprietary technology/agreement etc., application program 38 can communicate to connect the computing machine/equipment in the factory 10.Therefore, use OPC application program 38 to be communicated to connect the concrete example of the computing machine/equipment in the processing factory 10 although described herein, but those of ordinary skill in the art should be understood that various other methods that also can use the computing machine/equipment in the processing factory 10 that application program 38 is connected to.Usually, application program 38 can be stored the data of being gathered in database 43.
If collect statistics (or process variable data), then can use and check application program 40, so that handle these data by different way and/or (for example show a statistics of gathering or handling, be stored in the database 43), so that user maintainer for example, can determine better that unusual condition exists or prediction exists in the future, and take the corrective measure of trying to be the first.Criterion machine exploitation and executive utility 42 can use the one or more criterions that are stored in wherein, analyzing the data of gathering, thereby determine in the processing factory 10 that unusual condition exists or the predicted anomaly situation in existence in the future.In addition, exploitation of criterion machine and executive utility 42 can make operator or other user create the additional criteria for the treatment of by the execution of criterion machine, thereby detect or the predicted anomaly situation.
Fig. 2 shows the part 50 of the exemplary processing factory 10 of Fig. 1, carries out the mode of statistical data collection with specification exception situation prevention system 35.Though Fig. 2 shows the communication between the one or more data acquisition modules in unusual condition prevention system application program 38,40,42 and database 43 and HART and the Fieldbus field apparatus, but be appreciated that, similar communication can occur in unusual condition prevention system application program 38,40,42 and the processing factory 10 miscellaneous equipment and the device between, comprise equipment shown in Figure 1 and the device in any one.
The part 50 of processing factory 10 shown in Figure 2 comprises distributed process control system 54, this system has one or more process controllers 60, by I/O (I/O) card or equipment 68 and 70, it can be the equipment that meets any required type of any required communication or controller protocol, and process controller 60 is connected to one or more field apparatuss 64 and 66.Although field apparatus 64 is shown the HART field apparatus in the drawings, and field apparatus 66 is shown the Fieldbus field apparatus in the drawings, these field apparatuss can use any other required communication protocol.In addition, field apparatus 64 and 66 can be an any kind equipment, for example sensor, valve, transmitter, steady arm etc., and can meet any required opening, proprietary or other communication or sequencing agreement, should be appreciated that, I/O equipment 68 and 70 must with the protocol-compliant of field apparatus 64 and 66 employed needs.
In any case, can be by the one or more user interfaces of for example deployment engineer, process control operator, maintainer, plant manager, overseer's etc. factory personnel visit or computing machine 72 and 74 (it can be the personal computer, workstation etc. of any kind), hard wire or wireless communication configuration by can using any needs also used communication protocol any needs or that be fit to, for example the communication line or the bus 76 that realize of Ethernet protocol is connected to process controller 60.In addition, database 78 can be connected to communication bus 76, coming work as the data history records device, its collection and store configuration information and online process variable data, supplemental characteristic, status data and with processing factory 10 in process controller 60 and field apparatus 64 and 66 other relevant data.Therefore, database 78 can be used as configuration database and comes work to store current configuration, the control configuration information that this current configuration packet is drawn together the process configuration module and is used for Process Control System 54, they are downloaded and are stored in process controller 60 and field apparatus 64 and 66.Similarly, database 78 can be stored historical unusual condition prevention data, and it comprises the statisticss by field apparatus in the processing factory 10 64 and 66 collections, or according to field apparatus 64 and the 66 determined statisticss of process variable of gathering.
Though process controller 60, I/O equipment 68 and 70 and field apparatus 64 and 66 be arranged at downwards and spread in the harsh sometimes environment of plant usually, workstation 72 and 74 and database 78 be arranged at usually in the not too harsh environment that pulpit, maintenance room or other easy operating person, maintainer etc. use.
Usually, one or more controller application programs are stored and carried out to process controller 60, and it uses many control modules different, independent execution or piece (block) to realize control strategy.Each of these control modules can be made up of common alleged functional block, wherein each functional block is a part or subroutine of whole control program, and cooperate with other functional block (by so-called link communication), to realize the process control loop in the processing factory.As is well known, functional block can be the object in the object-oriented program agreement, it carries out a function in input function, control function or the output function usually, wherein input function for example with transmitter, sensor or other process parameter measurement device function associated, control function for example with the control program function associated of carrying out controls such as PID, fuzzy logic, output function is controlled some equipment, and for example operation of valve is so that carry out some physical function in processing factory 10.Certainly, also there is the complex function piece of mixing and other type, for example model predictive controller (MPC), optimizer etc.Though be appreciated that Fieldbus agreement and Delta
TMSystem protocol uses designed and the controlling models and the functional block that realize in the object-oriented program agreement, but control module can use the control program scheme of any needs to design, comprise for example sequential functional block, ladder logic etc., and be not limited to the functions of use piece or any other specific program technology designs.
As shown in Figure 2, maintenance work station 74 comprises processor 74A, storer 74B and display device 74C.Storer 74B stores in such a way with reference to the described unusual condition prophylactic applications of Fig. 1 program 38,40 and 42, promptly, make these application programs on processor 74A, to carry out, so that provide information to the user by display 74C (or any other display device, for example printer).
In addition, as shown in Figure 2, some in the field apparatus 64 and 66 (and may be whole) comprises data acquisition and processing (DAP) module 80 and 82.Though for the purpose of discussing, module 80 and 82 is described with reference to Fig. 2 as diagnostic module (ADB) in advance, wherein ADB is that the known Fieldbus equipment that can be increased to is to gather and to handle foundation fieldbus (Foundation Fieldbus) functional block of the statistics in the Fieldbus equipment, but module 80 and 82 can be maybe to comprise any other type blocks or the module that is arranged in process device, their collecting device data are also calculated or definite one or more statistical measures or parameter at these data, no matter and whether these functional blocks are arranged in Fieldbus equipment or meet the Fieldbus agreement.Although the module of Fig. 2 80 and 82 is shown as one of one of equipment of being arranged in 64 and equipment 66, but these or similar module can be arranged in many field apparatuss 64 and 66, can be arranged in miscellaneous equipment, for example controller 60, I/O equipment 68,70 or any equipment shown in Figure 1.In addition, module 80 and 82 can be arranged in any subclass (subset) of equipment 64 and 66.
Usually, module 80 and 82 or the subassembly of these modules, the data of process variable data for example in the collecting device, these modules are arranged in equipment, and for many reasons data are carried out statistical treatment or analysis.For example, show and make the module 80 relevant with valve to have the butterfly gate trace routine, this process analysis valve process variable data is to determine whether this valve is in blocked state.In addition, module 80 comprises one group of four statistic processess monitoring (SPM) module or cell S PM1～SPM4, gather process variable or other data in this valve, and the data of being gathered are carried out one or more statistical computations, thereby determine for example mean value, intermediate value, standard deviation, root-mean-square value (RMS), rate of change, scope, minimum value, maximal value of institute's image data etc., and/or detect in institute's image data such as incidents such as drift, deviation, noise, peak values.The concrete statistics that is produced not necessarily, the method that produces these data neither be necessary.Therefore, can produce dissimilar statisticss to replenish or to replace the data of above-mentioned particular type.In addition, various technology comprise technique known, can be used to produce these data.This term of statistic processes monitoring (SPM) module is used to describe the function of at least one process variable or other procedure parameter being carried out the statistic processes monitoring here, and can be carried out by the needed any software, firmware or the hardware that are arranged in equipment even are positioned at the device external of image data.SPM is appreciated that because SPM is arranged in the equipment that device data gathered usually, so can obtain more and process variable data more accurately qualitatively.As a result, the SPM module can be determined the statistical computation about the process variable data of being gathered better than the module of the device external of gatherer process variable data usually.
In another example, the module 82 of Fig. 2 shows that work is relevant with transmitter, and it can have the plugged line detecting unit, and the process variable data that this element analysis is gathered by transmitter is to determine whether have circuit blocked in the factory.In addition, module 82 comprises one group of four SPM module or cell S PM1～SPM4, they can gather process variable or other data in the transmitter, and the data of being gathered are carried out one or more statistical computations, with for example mean value of determining institute's image data, intermediate value, standard deviation etc.If desired, can be by above-mentioned United States Patent (USP) NO.6, the possible operation of module 80 and 82 is carried out or realized to 017,143 described mode.All comprise four SPM modules though module 80 and 82 is illustrated as each module, yet module 80 and 82 may have the SPM module of any other number therein, be used for gathering and definite statistics.Similarly, comprise detection software although module 80 and 82 is illustrated as, to be used for detecting the particular condition of processing factory 10, module 80 and 82 also can not have such software.And further, though SPM module discussed herein is illustrated as the subassembly of ADB, they can replace with the module of the independent setting (stand-alone) of the equipment of being arranged in.And, though SPM module discussed herein can be known foundation fieldbus SPM module, gather for example data of process variable data and so on but this term of statistic processes monitoring (SPM) module used herein is meant, and these data are carried out certain statistical treatment to determine for example module or the parts of any kind of the statistical measures of mean value, standard deviation etc.Therefore, this term is tending towards covering the parts that software or firmware or other are carried out this function, no matter whether these parts are forms of functional block or other type block, program, routine or parts, no matter and whether these elements meet foundation fieldbus agreement or other agreement, for example agreements such as PROFIBUS, WORLDFIP, Device-Net, As-Internet, HART, CAN.
In one embodiment, each the SPM module in ADB 80 and 82 can be (active) that activate or unactivated.The SPM module that activates is the module of current monitor procedure variable (or other procedure parameter), and unactivated SPM module is the current module that does not have the monitor procedure variable.Usually, the SPM module is defaulted as un-activation, and therefore, each all must be configured to the monitor procedure variable separately usually.Fig. 3 shows exemplary configuration and shows 84, and it can offer user, slip-stick artist etc., to describe and to change the current SPM configuration of equipment.As show shown in 84, the SPM module 1,2 and 3 of particular device all has been configured, and SPM module 4 also is not configured.The parameter reference (being monitored parameter) in a particular module among SPM module SPM1, the SPM2 that is configured and the SPM3 each and the equipment (by module tag (block tag) expression), module type, this module and the user command of expression SPM module monitors function are relevant.And further, the SPM module that each is configured comprises that the statistical parameter that is determined treats the one group of threshold value that compares with it, for example comprise mean value boundary, high deviation limits (a too big value of deviation in its regulation expression signal) and low dynamically (low dynamics) boundary (a too little value of deviation in its regulation expression signal).Fundamentally, detect the variation of mean value and can represent that this process upwards is offset or offsets downward, detect high deviation and mean that the parts in this process (are for example experiencing unforeseen noise, cause by the vibration that increases), and detect low deviation and mean that process signal is just filtered, or parts are becoming suspicious staticly, have for example blocked valve.And further, can reference value be set for each SPM module, for example mean value and standard deviation.These reference values can be used for determining whether to satisfy or exceed each boundary of equipment.The SPM module 1 and 3 of Fig. 3 all activates, because they have received user's order to start monitoring.On the other hand, SPM module 2 is unactivated, because it is in idle condition.And in this example, the SPM function is all enabled entire equipment, shown in square frame 86, and is set to every monitoring in five minutes or calculating, shown in square frame 88.Certainly, authorized users can be reshuffled the SPM module in the equipment, to monitor other module and to have other threshold value, reference value etc., for example other functional block in the watch-dog, with equipment in these or other other relevant parameter of module.
Though some the statistics monitoring module shown in the demonstration 84 of Fig. 3, yet be appreciated that other parameter also can or monitored in addition.For example, can calculate the statistical parameter relevant with process with reference to the SPM module or the ADB of Fig. 2 discussion, and can be based on some alarm of change triggers of these values.By the mode of example, the SPM module of Fieldbus type can the monitor procedure variable and 15 the different parameters relevant with this monitoring is provided.These parameters comprise module tag, module type, mean value, standard deviation, inequality, standard deviation variation, benchmark mean value, base standard deviation, high deviation limits, low dynamic boundary, mean value boundary, state, parameter reference, timestamp and user command.Current, two parameters the most useful are considered to mean value and standard deviation.But other useful SPM parameter is benchmark mean value, base standard deviation, inequality, standard deviation variation and state usually.Certainly, the SPM module can be determined the statistical measurement or the parameter of any needs, and other parameter of a relevant particular module can be provided to user or request applications.Therefore, the SPM module is not limited thereto these of place discussion.
With reference to Fig. 2, by bus or communication network 76 and controller 60, the SPM module (SPM1-SPM4) in the field apparatus is available to the external client, for example concerning workstation 74.Additionally or alternately, by for example opc server 89, (parameter and the out of Memory of SPM1～SPM4) produce or gather are available to workstation 74 by the SPM module in ADB 80 and 82.This connection can be that wireless connections, hard wire connect, batch (-type) connects (for example, using the connection of one or more portable sets) or use any needs or any other communicating to connect of needing of suitable communication protocol.Certainly, any communicating to connect described herein can be used the OPC communication server, integrates the data that (integrate) receives from dissimilar equipment according to common or compatible form.
And further, in the equipment that the SPM module can be arranged in the main process equipment, other is not field apparatus or in other field apparatus, to carry out the statistic processes monitoring to for example gathering or produce the device external of the raw data of original procedure variable data.Therefore, for example the application program 38 of Fig. 2 can comprise one or more SPM modules, and it gathers the original procedure variable data by for example opc server 89, and calculate some statistical measurement or parameter, for example the mean value of this process variable data, standard deviation etc.Though these SPM modules are not arranged in the equipment of image data, and because need for the communication of these data, therefore make the SPM module can not gather process variable data as much as possible usually to carry out statistical computation, but these modules help to determine statistical parameter for equipment, perhaps do not have or do not support process variable in the equipment of SPM function.In addition, along with the raising of technology, the handling capacity utilized of network can increase along with the time, and the SPM module that therefore is not arranged in the equipment of gathering raw data can be gathered more process variable datas, to carry out statistical computation.Therefore, in the following discussion, be appreciated that, described any statistical measurement or the parameter that produces by the SPM module, can produce by the SPM module, for example produce, perhaps by main frame or comprise that the SPM module in the equipment of other field apparatus produces by the SPM1-SPM4 module in ADB 80 and 82.
Increase along with statistical data collection module or SPM in the processing factory, it is helpful having so a kind of automechanism, be that its SPM module from different equipment is gathered statistical parameter and provided testing result with vectoring information and to expert system, with further integrated data and make decisions.In fact, at present, check that the whole statistic processes data in the large-scale process are very to bother and oppressiveness.Current, people must create an OPC client, and it monitors interested each SPM parameter respectively, and for this reason, must dispose each equipment that is used for the SPM collection respectively.As implied above, the configuration of statistics and check and be very consuming time and be vulnerable to the infringement of mistake.
Configuration and data collection application 38 are suitable for disposing automatically the SPM module in the equipment of for example valve, transmitter etc., thus during process operation from these SPM module gatherer processes available SPM data.Fig. 4 is the process flow diagram of an example technique, and this technology can be used by application program 38, with the equipment in the allocation processing plant, thereby gathers the SPM data and gathers these data automatically in the operating period of processing factory 10.In Fig. 4, the action that the circle expression is carried out in processing factory by application program 38, and rectangle is represented by application program 38 uses or the object that produces or (item).Be appreciated that, though this example has been discussed from using the Fieldbus agreement and having the particular type transmitter of the Fieldbus module of gathering statistics and has been gathered the SPM data, but this technology or similar technique can be used for from using the miscellaneous equipment of other communication and functional module agreement, or from the parts of the miscellaneous equipment of service routine example rather than functional module sequencing example or these equipment, gather statistics (or other parameter).
In any case, in first frame 92, (for example, processing factory) hierarchy comprises statistical data collection module (for example, equipment ADB) with row in definite processing factory to application program 38 scanning process Control Network.Although frame 92 can search for other type statistics data acquisition module and or except the SPM of Fieldbus type among the ADB, and this method is not limited to use the SPM module among Fieldbus ADB or the Fieldbus ADB, but for the purpose of discussing, still the "as if" statistics data acquisition module adopts the SPM modular form among the above-mentioned Fieldbus ADB.In one embodiment, opc server (for example, the server 89 of Fig. 2) can allow for example the client access control and the facility information of application program 38.For example, OPC controls 2.0 products automatically the standard method of browsing the PC server content is provided, and these or other browsing method can be used for the hierarchy of automatic conversion OPC to find out the equipment that comprises ADB.In addition, New O PC specification comprises the XML definition, and it can be used for integrated data and it can be utilized in network environment.
Fig. 5 shows the part of exemplary factory hierarchy 94, and this hierarchy 94 is created by opc server, has just described equipment and other parts by the processing factory of opc server scanning.Hierarchy 94 top has the node 96 and 98 that is called module and input and output (IO), and wherein module node 96 comprises control strategy information, and IO node 98 comprises hardware/facility information.Shown in the exemplary hierarchical structure of Fig. 5, IO node 98 comprises and controller (CTLR), card (C) and the relevant child node of port (P), wherein, in this example, port (P) is relevant with the Fieldbus section (segment) in actually existing in controller network.Further downwards, Fieldbus equipment is listed under their port separately in this hierarchy.In the example of Fig. 5, each Fieldbus equipment that comprises ADB comprises the node that is called frequency converter (TRANSDUCER) 800 or frequency converter 1300 under this equipment.(in Rosemount 3051F equipment, ADB is called as frequency converter 800, and in Rosemount3051S equipment, this ADB is called as frequency converter 1300).A node 100 that is called as frequency converter 800 is shown in the hierarchy of Fig. 5.ADB node 100 comprises the diagnostic message of being concerned about.In particular case, statistic processes monitoring (SPM) parameter in 38 pairs of ADB nodes 100 of application program is interested, and in the hierarchy of Fig. 5, ADB node 100 is launched so that some parts relevant with the ADB in the Rosemount3051F equipment to be shown.Certainly, the title example of the known function piece that just provides by a tame well-known manufacturer of title " frequency converter 800 " and " frequency converter 1300 ".Other ADB module or SPM module can have other title, and/or these titles can be different in a system that is different from the system that uses OPC.In other implementation, different titles can be corresponding developed afterwards and/or was provided and/or according to the ADB module or the SPM module of other frequency converter piece of describing in the foundation fieldbus specification, functional block etc. by other manufacturer, maybe can be what its intelligence communication agreement in office (for example, digital protocol) module in or other software part, for example any element in the several Profibus, the HART that name, CAN, AS-Interface, agreements such as HTML, XML.
For finding the SPM module among ADB and the ADB, OPC hierarchy 94 is changed or searched for to frame 92 (Fig. 4) automatically, to comprise all devices of ADB in the positioning plant.Certainly, frame 92 can be programmed for understanding in advance and set 94 employed forms by OPC, so that frame 92 can be changed or browse tree 94, thereby finds out the equipment that comprises ADB in the best way.Though method described herein is set based on DeltaVOPC,, can make amendment to this method for other opc server and by the plant hierarchy that scan tool produced of other type.
Searching for hierarchy or setting, a balance is arranged usually at 94 o'clock between speed and the robustness.Especially, with regard to finding out all equipment with ADB, search hierarchy 94 can not be absolutely reliably usually, but only can find out the equipment that some have ADB.As a rule, the method for finding out the equipment with ADB is accurate more, and this method will be slow more.For instance, if different manufacturer has the equipment that shows in OPC tree 94, and this equipment have with the 3051F transmitter in the module of ADB module same names, search for so hierarchy possible errors ground with this Equipment Inspection for having ADB.Otherwise, if frame 92 attempt only to guarantee that by searching for a large amount of child nodes the location really has the node of ADB, thereby eliminate this problem, the speed of this method will reduce so.
Under any circumstance, in one embodiment, frame 92 can be searched for hierarchy or set each node in 94, so as in some equipment known each node in location with title relevant with ADB.Though in some cases, in for example large-scale processing factory, this can consume obviously many search times, and it is the accurate method of finding out each ADB and then look for each SPM in processing factory.On the other hand, frame 92 can be searched for hierarchy downwards, up to arriving or finding the node with title relevant with known statistics monitoring module, for example frequency converter 800 or frequency converter 1300 or any other are made the specific names that is used for representing a known statistics monitoring module by some equipment manufacturers.If find such node, relevant with this node so father (parent) node can be used as the equipment with ADB and is detected.Though each node that this method does not resemble in specific OPC hierarchy of search or the tree has robustness so, it is fast that this method should be wanted.If but another manufacturer produces the equipment of the OPC node with frequency converter 800 by name, this method still will wrong ground detect this miscellaneous equipment for having ADB so.
Alternately, frame 92 can be searched under each node, looks for the additive term that has with known ADB related names in the equipment of the unique relevant or hint ADB of known and ADB.Therefore, frame 92 can located have the known node that uses by manufacturer of at least one family with clear and definite ADB title after, the search child node is to check characteristic/module tag. whether son symbol string (Charcteristic/BLOCKTAG.STRING) has " advanced diagnosis (ADVANCED DIAGNOSTICS) " value.In this example, only having the characteristic/module tag of the equipment of ADB. character string OPC item has " advanced diagnosis " value.Though this method is to have very much robustness when only having the equipment of ADB in the location, this method need be passed through opc server slave unit read value, and this is than just browsing the longer time of OPC hierarchy significant need.Therefore, though this method is accurate, too slow for some situation.
The other method that can be implemented by the frame 92 of Fig. 4 is a search OPC tree 94, this method provides compromise between speed and robustness, it is included in the node search OPC hierarchy down that has usually the known name relevant with ADB, to search the child node that also has the common name relevant with ADB.For example, this method can begin and Searching I O node 98 from the top that OPC sets 94 (Fig. 5).Then, this method each child node under can recursive search IO node 98.If find child node (the perhaps known and statistics monitoring module of frequency converter 800 by name or frequency converter 1300, the name of relevant other of ADB for example), then this method checks this node whether to have the child node of a SPM_ACTIVE by name, perhaps concrete with add up relevant any other child node of monitoring module.If for example finding SPM_ACTIVE under frequency converter 800 nodes, then frame 92 is the equipment that comprises ADB with the father node detection of frequency converter 800 nodes.
Certainly, frame 92 can use any in these technology, and perhaps the combination of these technology or any technology search that other needs have the equipment of ADB (and therefore having SPM).For example, a kind of implementation can try hard to discern at least known all ADB that realized by the equipment of manufacturer of at least one family, but may be able to also may not discern all ADB in the processing factory.As another example, an implementation can try hard to discern the known all ADB that realized by the equipment of different manufacturers of several families.And, though being described as, this scanning step use the OPC hierarchy to carry out, hierarchy that produces by opc server just, but this method can be applicable to or uses in the hierarchy that is produced by miscellaneous equipment, for example the data history records device of the configuration hierarchy in controller, the storage processing factory, the workstation of memory device hierarchy etc.Therefore, other implementation need not use opc server and/or OPC hierarchy, but may use a lot of other computing equipment, communication protocol and hierarchy agreements, it for example comprises, known and up-to-date computing equipment, communication protocol and hierarchy agreement.Other implementation can use web server, XML and/or proprietary computing equipment and agreement for instance.
Finding and search comprises in the process of equipment of ADB, frame 92 can store detected have ADB, the tabulation of the equipment of SPM module or other categorical data acquisition module, shown in the square frame among Fig. 4 108.If desired, square frame 108 listed equipment can be presented at according to their hierarchy in the tree view.An example of the view 110 of this hierarchy as shown in Figure 6.Just as is understood, the hierarchy 110 that shows in Fig. 6 view is to show a subclass of shown hierarchy by the Control Network that controller produces, because be not that all devices of controlling in showing all comprises ADB usually.In fact, the view among Fig. 6 110 is actually the copy of the controller hierarchy that includes only the equipment with ADB.Just as is understood, each equipment of showing among equipment PT-101 and PT-102 (being connected to the port P01 of card C01 of input-output apparatus I01 of the controller of CTLR-002EC6 by name) and equipment PT-103, FT-201 and the FT-201 (being connected to the port P02 of card C01 of the input-output apparatus I01 of the controller that is called CTLR-002EC6) of the demonstration among Fig. 6 all has ADB.
In order to read any SPM parameter in the slave unit, need know the OPC item ID of this parameter usually.Usually, promptly in Fieldbus SPM module, the OPC item ID of a SPM parameter comprises the device id that follows hard on this detailed description (specifier).For positioning equipment ID, frame 92 can determine that the device node that comprises ADB searches child node SPM_ACTIVE to each.Next, frame 92 can obtain the OPC item ID of node " CV ".For example, OPC item ID can be " equipment (DEVICE): 0011513051022201100534-030003969/800/SPM ACTIVE.CV ".Device id is that OPC item ID deducts suffix " SPM ACTIVE.CV ".Therefore, in this example, device id is " equipment: 0011513051022201100534-030003969/800/ ".Certainly, this only is a kind of mode of determining device id in the OPC system, also can use or replace other technology of use.
In any case with after determining to have the equipment of ADB, application program 38 is known or can easily be determined device label, device id and device location for each equipment of these equipment at frame 92 scanning hierarchies.For comprising 5 single systems with ADB equipment, an example of these data is as shown in the table.
Table 1
| Equipment | Device id | Device location |
| Label | ||
| PT-101 | Equipment: 0011513051022201100534-030003969/800/ | IO\CTLR-002EC6\IO1\C01\P01 |
| PT-102 | Equipment: 0011513051021801020526-030003576/800/ | IO\CTLR-002EC6\IO1\C01\P01 |
| PT-103 | Equipment: 0011513051110901091012-030007090/800/ | IO\CTLR-002EC6\IO1\C01\P02 |
| FT-201 | Equipment: 0011513051110901101045-020008632/800/ | IO\CTLR-002EC6\IO1\C01\P02 |
| FT-201 | Equipment: 0011513051110801210450-020008576/800/ | IO\CTLR-002EC6\IO1\C01\P02 |
Refer again to Fig. 4, which equipment that next frame 114 can be determined to be stored in the square frame 108 has been configured to carry out the statistic processes monitoring.For carrying out this function, frame 114 can read SPM_ACTIV E.CV value for each equipment that is stored in the square frame 108 from opc server.For example, to the PT-101 in the above table, frame 114 can read OPC item, i.e. equipment: 0011513051022201100534-030003969/800/SPM ACTIVE.CV.This OPC item can value be 0 or 255.In the example of FieldbusSPM module, if this value is 0, the SPM module is forbidden by this equipment so, if this value is 255, then the SPM module is enabled by this equipment.In case whether check SPM is enabled by each equipment, frame 114 just can be divided into two classes to all devices, promptly has the equipment and the equipment with the SPM that does not also dispose of the SPM that has disposed.The classification of these equipment or tabulation are shown in the square frame 116 and 118 of Fig. 4.
Determine to list in after whether SPM in each equipment in the square frame 108 enable at frame 114, frame 120 can be enabled the equipment of SPM to each, and just those each SPM modules of listing in or being stored in the equipment in the square frame 116 are carried out state-detection.Frame 120 is main carries out these steps determining the current monitor procedure variable that whether has been configured to of each SPM module in enabling the equipment of SPM, and if be configured to determine monitoring which process variable.In this example, by reading the state of SPM module, can determine that the SPM module is current whether just at the monitor procedure variable.In the FieldbusSPM module, can be by from opc server, reading SPM[n] the STATUS.CV item comes detected state.Therefore, for example, be the state of the SPM module 1 among the fetch equipment PT-101 from above table, frame 120 can read OPC item ID, i.e. equipment: 0011513051022201100534030003969/800/SPM1 STATUS.CV.
Usually, state value is a scope in 0～255 8 figure places.State is 8 not combinations of coordination, can be out or closes.These positions are: un-activation (1), study (2), verification (4), nothing detect (8), inequality (16), high deviation (32), low dynamically (64) and not permission (128).All licensed SPM modules that but do not have to dispose have unactivated state.If the state of SPM module is un-activation or not permission, then frame 120 can determine not monitor this module, and this is because it does not produce any Useful Information.Yet, if state to be other any may situation, frame 120 can be monitored the SPM module.
Similarly, frame 122 can dispose does not automatically have the individual device (that is, the equipment of listing in the square frame 118) of enabling SPM, thereby enables at least one the SPM module in these equipment, detecting and the monitor procedure variable, and therefore generation about the statistics of this process variable.In many cases, for example have under the situation of gentle Si Mangte (Rosemount) 3051F and 3051S transmitter, have the not SPM of configuration when equipment dispatches from the factory, this requires user human configuration SPM in individual device usually.In the processing factory with thousands of equipment with ADB, this is a very dull process.In order to alleviate this human configuration, frame 122 disposes at least one SPM module automatically for each equipment.In order to carry out this configuration, the indication of special process variable to be monitored in the equipment can be determined or be stored in to frame 122.This variable may be arbitrary in available other functional block variable (input and output) in main procedure input, the output of PID module or the Fieldbus equipment.The indication to be monitored about which variable can be provided with in layoutprocedure, specified according to this situation basis in one case by the user, perhaps specified on the whole before program 38 operations by the user.
Though can monitor any process variable, the logical variable of monitoring for the statistics purpose is the main analog input of equipment.For gentle Si Mangte 3051F/S transmitter, this variable is measured pressure or flow (for example, pressure reduction).Therefore, frame 122 can be configured to dispose a SPM module automatically in the ADB of equipment, thus the main analog input or the output of watch-dog.If desired, user's artificial other SPM module of configuration device still.Alternately, frame 122 can be the tabulation of every type device storage process variable to be monitored, and can under any circumstance select or determine those process variable to be monitored with this tabulation.Though frame 122 is described as single SPM module in the configuration device herein to monitor a process variable, frame 122 can dispose at least two SPM modules in particular device, thus monitoring at least two process variable relevant with this equipment.
In addition, the DeltaV opc server allows user's (giving enough administration authorities) will be worth the particular item in the write device.Therefore, by in opc server, writing suitable item, the SPM parameter in can change equipment.Therefore, by a train value is write opc server, frame 122 can be the SPM of monitoring at primary process variable with equipment disposition.In a special example, the value that is written to opc server is as shown in the table.
Table 2
| OPC item ID | Value |
| [device id] SMP1_BLOCK_TAG.CV | AI1 |
| [device id] SMP1_BLOCK_TYPE.CV | 257 |
| [device id] SMP1_PARAM_INDEX.CV | 8 |
| [device id] SMP1_USER_COMMAND.CV | 2 |
| [device id] SMP_ACTIVE.CV | 255 |
Herein, [device id] device id that should be used in the table 2 to be found replaces.Therefore for equipment PT-101, first OPC item that write is: equipment: 0011513051022201100534-030003969/800/SPM MONITORING CYCLE.CV.After all these are written to opc server, dispose this equipment with the principal pressure variable in the monitoring SPM1 module.Certainly, this only is written to an example of particular types SPM module in the Fieldbus equipment, be to be understood that write other type SPM module other method too or replaceable, and write command is determined by the employed communication protocol of those SPM modules.
In any case one group or a SPM module to be monitored that is listed as in the equipment that has ADB have been created in the frame 120 of Fig. 4 and 122 operation.These row are illustrated as in the frame 124 that is stored in Fig. 4, and are perhaps associated.In addition, the frame among Fig. 4 126 has been stipulated one group of SPM parameter for each SPM module to be monitored that application program 38 should be monitored.This SPM Argument List 126 can be before application program 38 operation or operating period specify by the user or select, the different SPM modules that perhaps can be respectively to be monitored during layoutprocedure are selected independently or are specified.Following table illustrates all SPM parameters that can read from opc server for each Fieldbus SPM module.
Table 3
| Parameter name | The OPC suffix |
| Module tag | SPM[n]_BLOCK_TAG.CV |
| Module type | SPM[n]_Block Type.CV |
| Average | SPM[n]_Mean.CV |
| Standard deviation | SPM[n]_Stdev.CV |
| Change in Mean | SPM[n]_Mean_Changes.CV |
| Standard deviation changes | SPM[n]_StDev_Changes.CV |
| Baseline mean | SPM[n]_Baseline_MEAN.CV |
| Base standard is poor | SPM[n]_Baseline_StDev.CV |
| The High variation boundary | SPM[n]_High_Variation_Lim.CV |
| Low dynamic boundary | SPM[n]_Low_Dynamics_Lim.CV |
| The average boundary | SPM[n]_Mean_Lim.CV |
| State | SPM[n]_Status.CV |
| Parameter reference | SPM[n]_Param_Index.CV |
| Timestamp | SPM[n]_TimeStamp.CV |
| User command | SPM[n]_User_Command.CV |
Yet, for each SPM module to be monitored, may must all these parameters to be monitored.In fact, if too many item to be monitored, opc server might transship so.Therefore, application program 38 can provide a kind of mechanism, can make the user select one group of SPM parameter to be monitored by this mechanism.Fig. 7 shows an example screens that allows this selection, and wherein the user can check the SPM parameter that each SPM module that the user wishes frame 124 is identified is monitored.
Frame 128 use SPM parameter to be monitored tabulation (such as frame 126 sign) and the tabulation of SPM module to be monitored (such as frame 124 sign), be structured in during the process operation one group of SPM OPC item will monitoring by application program 38.Shown in frame 130, frame 128 can be stored this group OPC item, to be used for the subsequent step of monitor procedure.Generally speaking, frame 128 is created the SPM OPC item that is used for each SPM parameter (representing with frame 126) to be monitored for each SPM module (representing with frame 124) to be monitored.In other words, in case provided one group of SPM module and one group of SPM parameter to be monitored to be monitored in these modules each, frame 128 just makes up one group of OPC item to be monitored, as each the OPC item that may make up that is used for SPM module to be monitored and SPM parameter to be monitored.Therefore, for instance, if there are 10 SPM modules to monitor, and each SPM module has 5 SPM parameters to monitor, and frame 128 will be created one and add up to 50 OPC item so.In this embodiment, OPC item ID is a device id and from the combination of the OPC suffix of last table.For example, for the average of SPM1 among the fetch equipment PT-101, OPC item ID will be: equipment: 0011513051022201100534030003969/800/SPM1 MEAN.CV.
In frame 130, discerned and stored after all OPC items, frame 132 and 134 variations of monitoring SPM parameter during process operation.For example, some SPM parameter may change every 5-60 minute according to the SPM modules configured, and other SPM parameter may only just can change when configuration SPM module.As a result, when the process of monitoring SPM parameter began, frame 132 can at first read the currency (the OPC item by frame 130 is specified) of all SPM parameters.In one embodiment, frame 132 can be utilized as read that each OPC item ID calls read (SyncRead) function synchronously, carry out this and read.Shown in the frame 136 of Fig. 4, reading of each SPM parameter produces one group of SPM data point.
After reading the SPM parameter for the first time, frame 134 can be waited for the variation of SPM parameter.That is to say that with after obtaining first group of SPM data point, frame 134 receives or obtains expression and monitors the additional data that any one SPM parameter changes at the initial value that reads each SPM parameter of being monitored from opc server.For instance, according to the SPM modules configured, average and standard deviation may change once every 5-60 minute.However, when any one SPM parameter changed, opc server all can produce a data variation (DataChange) incident, and this incident is caught by the OPC client such as application program 38.Alternately, frame 134 can be periodically, or at the current time poll or read each SPM parameter of being monitored, to obtain new data point (frame 136).In this manner, even the SPM parameter does not change, also read this SPM parameter.Certainly, frame 134 can be operated during process operation constantly receiving new SPM parameter, and this SPM parameter is stored in the database checks for the user, is perhaps used by the following machine of criterion in greater detail, perhaps is used for any other purpose.Certainly, if desired, the routine 90 of Fig. 4 can detect with HRP-configured master device in SPM module or other statistical data collection module so that make these SPM modules provide statistical measurement or parameter to other element of unusual condition prevention system 35 (Fig. 1).
In fact, any moment after reading any one SPM data point of frame 136, frame 138 can or be kept at (for example database 43 of Fig. 1 and Fig. 2) in the local data base with these data point storages, so that the reference that these data points can be carried out being used in the future trend of checking or other checking purpose.In addition, frame 140 can be used for any purpose, show the SPM data with any desired or useful form to the user, for example detect or prediction processing factory in unusual condition.If desired, frame 140 can be realized by the application program 40 of checking shown in Fig. 1 and Fig. 2.
Generally speaking, check that application program 40 (can be carried out by the frame 140 of Fig. 4) can show the SPM parameter to the user with any desired or useful form, so that make the user can for example just view up-to-date SPM data at a glance.For example, check that application program 40 can utilize conventional browser escope to show the SPM data.In Fig. 8, described an example of this demonstration, the browser hierarchy 110 of Fig. 6 wherein is provided in the left side of display screen, simultaneously for each SPM module to be monitored, describe the SPM parameter of being monitored (screen as Fig. 7 is specified) on the right side that shows 115.Should be noted that in display part 115 and the SPM data are classified, so that search or check the data relevant easily with particular device according to equipment.Certainly, the user can select any one or a node in hierarchy 110, so that check the SPM data relevant with these or node.In addition, if desired, check that application program 40 can provide the browser display such as Fig. 9, the SPM parameter that it comprises the SPM module component and is monitored for the SPM module component.Therefore, in the exemplary hierarchical structure 141 of Fig. 9, the SPM module 142 that is called SPM1 is illustrated as the equipment that is arranged in 3051-Flow by name.The SPM parameter that element 143 expression of SPM1 module below 142 monitored, and can be used for the user and check.In this case, these parameters comprise average, Change in Mean, standard deviation, standard deviation variation, average/standard deviation and standard deviation/average.
If desired, check that application program 40 can allow or make the user at the scene in the equipment, even in the main frame at these module places or miscellaneous equipment, add or reconfigure one or more SPM modules.Figure 10 illustrates a display screen 144, and in this case, shown in window 145, display screen 144 makes the user add new equipment to the port of P01 by name, also can add or dispose the SPM module in this equipment in addition.Here, this SPM module called after SPM1, its relevant with device label FT3501-COLD1 (it is shown in the hierarchy in screen 144 left sides as equipment 3051_LEVEL), and with the OUT parameter or the variable relevant (operating this parameter or variable) of the analog input functional module of AI1 by name.In this case, check (being to be monitored) SPM parameter that application program 40 also makes the user specify to be concerned about, and for the baseline value and the threshold value of this SPM module, for example average, Change in Mean, standard deviation change or the like.
No matter in addition, check that application program 40 can make the user can handle whole hierarchy, obtaining the checking of particular types data, be directly from the data of SPM module (or other monitoring module), still the data that generate by for example application program 40.For example, Figure 11 illustrates a screen display 146, and it has described the plant hierarchy 147 in screen left side, and with the hierarchy of screen 146 right side views 148 in device-dependent one or more SPM or other module.In case selected a SPM module (being the SPM1 of 3051S-1 equipment in this case), the user just can use drop-down or pop-up window 149 to select to check mode from the data of this SPM1 module.In Figure 11, the user has selected to check trend map, and the concrete SPM supplemental characteristic (or its combination) that further drop-down or pop-up window can specify the user will to show in trend map.In this case, be to be understood that the data combination that the data with some possibility type of trend can be defined as from one or more SPM modules, and can in main frame (for example by application program 40), perhaps in field apparatus that can have access to this raw data or miscellaneous equipment, calculate these combinations.
Figure 12 illustrates screen 146, and wherein the user has been chosen in and has directly checked data in the pop-up window 149.Certainly, to select can be different to the data in further pop-up window here, and can specify the raw data of being gathered or being generated by the SPM module, and need not be provided at the option (for example average/standard deviation, or the like) of generation data in the main process equipment.Certainly, be to be understood that application program 40 can obtain the data from the SPM module, perhaps in some cases, can generate this data according to raw statistical data from the collection of SPM module.Further, can also provide the view of other type or option to check data (or it is from the SPM module, or the data that generate according to the data from the SPM module), for example histogram.Equally, the user can use screen 146 and pop-up window 149 to carry out other function, for example deletes the SPM data, begins new data acquisition circulation, or the like.
Figure 13 illustrates and can show the curve of SPM average to the time by exemplary trend Figure 150 of application program 40 generations.In this showed, the user can use control knob 152 to look back before or data afterwards, turns to the beginning or end of data, boundary in the search data or the like.In any case all trend window as shown in figure 13 make the user can check the historical Appearance of arbitrary SPM parameter.According to process, might be based on the trend of various process variable, the characterization abnormality.Yet in fact the user can do any not restriction to the statistic processes data, is to be understood that the user can use these data to be used for other purpose, current in detecting processing factory or in the future the unusual condition.In addition, the user can check the statistics of being gathered with any form or view that makes these data be easy to and read, understand and use, with the incident in detection and the prediction processing factory.
A glance just can find out that the figure of Figure 13 looks like the time dependent regular graph of process variable.Yet, should be noted in the discussion above that this figure is not the simple time dependent curve of process variable data, but the curve of institute's calculation process variable average at certain time intervals.Although might use DCS historical record device to come the average of drawing process variable to the curve of time, difference herein is: the average of process variable is in usually initial image data and obtains with faster rate in the equipment of these data and calculate.Therefore, should believe that measuring noise can not occur by the degree among the figure of data history records device establishment in the figure of Figure 13.In addition, should be more accurate such as the statistical measurement of average, because it is usually based on more image data.
Similarly, application program 40 can be drawn any other SPM parameter (for example, standard deviation, Change in Mean, standard deviation change or the like) to the curve of time, and any mathematical of SPM parameter combination (for example, standard deviation/average or the like) is to curve of time.And application program 40 can place the combination in any of these curves on the same width of cloth figure or the same page, so that make the relatively user is more prone between different statisticss.Figure 14 illustrates the set of diagrams of the statistical measurement of various process variable on the frame at one time, and all these figure can show the user in the same time on same display screen, perhaps show the user in different time on identical or different display screen.In Figure 14, upper left Figure 156 has drawn the curve of standard deviation to the time, top-right Figure 158 has drawn the curve of average/standard deviation to the time, Figure 160 of lower left has drawn on the same ratio chi three different averages (from different SPM modules) to the curve of time, and bottom-right Figure 162 has drawn on the same ratio chi three standard deviations (from different SPM modules) to the curve of time.Certainly, check that application program 40 can show any SPM parameter of monitoring on a width of cloth figure, or any mathematical of these parameters makes up time dependent curve, and the time dependent curve of different SPM parameters (or its mathematical combination) that can show arbitrary number on same width of cloth figure understands to help the user what situation has taken place in the processing factory.
Statistical Process Control is through being usually used in process control industries, to determine that certain process variable is whether beyond permissible boundary.(UCL, LCL), (USL, LSL), they can calculate based on the SPM data of being gathered by application program 38 to also have set upper limit and regulation lower limit for common existing upper control limit and lower control limit.In an example, control limit can be expressed as UCL=μ+3 σ and LCL=μ-3 σ, and wherein μ and σ are respectively that baseline mean and base standard are poor.In addition, the regulation boundary can be expressed as:
Δ wherein
μNumber percent average boundary for user's appointment.Certainly, check that application program 40 can directly calculate these values, perhaps can allow the user to import these values.
These or similarity have been arranged, checked that application program 40 can draw the distribution plan of average with respect to baseline mean and control limit, the visualization display when factory's run duration reaches or exceed the average boundary is provided thus.This result is a histogram that seems to be similar to Figure 166 among Figure 15 in essence.Just as is understood, upper control limit and lower control limit are represented with line 167 and 168 respectively, and set upper limit and regulation lower limit are represented with line 169 and 170 respectively.In addition, drawn average point (average that is each value is counted out) in online 172, and utilized Nogata Figure 174 to draw the baseline mean point.Shown in Figure 166, if process is under the control, so all data all are positioned in the boundary.If there is unusual condition, some data may exceed control limit or regulation boundary 167-170 (dropping on beyond the described boundary) so.In addition, Figure 166 is different from the histogram of standard, because Figure 166 has drawn the average (and baseline mean) of process measurement, rather than process measurement self.
If desired, check that application program 40 can add all control limits as discussed above and regulation boundary in the curve of statistical measurement (for example intermediate value etc.) to the time of average, standard deviation or any other expectation to.When these boundaries are added to average to the curve of time on the time, resulting curve is called X control chart (X-Chart).16 illustrate the example of the X control Figure 178 that is used for average statistical, and wherein average is represented with line 180 curve of time, and upper control limit and lower control limit represent with line 181 and 182 that respectively set upper limit and regulation lower limit are represented with line 183 and 184 respectively.
In this case, may preferably adjust, not draw actual process variable, but draw the average that goes up at certain time intervals because check application program 40 to the calculating of upper control limit and lower control limit.Be minimized owing to measure noise, therefore the same deviation that does not exist people in the standard x control chart of drawing process variate-value, to see.A kind of may the adjustment that can carry out upper control limit and lower control limit is with the square root of 3 σ part divided by the number of the data point that is used for calculating each average.According to this formula, can the following calculation control upper limit and lower control limit:
N=(monitoring period) * (60) * (per second sampling) wherein
Herein, monitoring period is the number of minutes of computation of mean values and standard deviation.Can use 15 minutes default value.The sampling of per second is based on the sampling rate of the equipment of measuring, for instance, although can also use other sampling rate, sampling rate is 10 for gentle Si Mangte Rosemount 3051F transmitter, and is 22 for gentle Si Mangte Rosemount 3051S transmitter.
In addition, application program 40 can produce the S control chart, has wherein drawn standard deviation to the curve of time, and control limit and regulation boundary.In this case, can be as the upper control limit of giving a definition, lower control limit and set upper limit and regulation lower limit:
Δ wherein
HVBe user-defined number percent High variation boundary, and Δ
LDBe user-defined low dynamic boundary, and Δ
LD＜0.
Figure 17 illustrates the example of S control Figure 190.Herein, standard deviation is drawn with line 192 curve of time, and upper control limit and lower control limit are drawn with line 193 and 194 respectively, and set upper limit and regulation lower limit are drawn with line 195 and 196 respectively.In the example of Figure 17, the standard deviation of process variable is crossed over the manyfold of upper control limit and lower control limit, and crosses over the doubly a lot of of set upper limit and regulation lower limit, therefore shows current potentially or unusual condition may occur in the future.
In addition, application program 40 can be determined other statistical measurement or value according to the data of being gathered.For example, application program 40 can be calculated distribution index or the measurement of variable x according to following formula, and it can comprise any statistical variable:
And can calculate related coefficient between two variablees (can comprise statistical variable) according to following formula:
In another example, can calculate two related coefficients between the variable according to following formula:
Certainly, check that application program 40 can be carried out according to intrasystem needs or demand other of any variable (comprising statistical variable and process variable) calculated, so that determine one or more unusual conditions in the processing factory.Therefore, for instance, application program 40 or some routine wherein can be carried out principle components analysis, regretional analysis, analysis of neural network or to any other unitary variant analysis or multivariable analysis of institute's image data, with execute exception condition detection and prevention.
Generally speaking, the figure of Figure 13, Figure 14, Figure 16 and Figure 17 is to draw the curve of one or more SPM parameters to the time.Yet, check that application program 40 can provide the figure of the degree of correlation between the irrelevant one or more SPM variablees of expression or diagram and time.In an example, check that application program 40 can produce to draw the scatter diagram of a SPM parameter with respect to another SPM parameter.Check that application program 40 or user can determine related coefficient, this related coefficient has represented how two SPM parameters (or certain combination of two SPM parameters) are associated.Figure 18 illustrates and draws two SPM Mean Parameters distribution Figure 200 relative to each other.Here, can always find out the basic linear characteristic (promptly when an average increased, another also trended towards increasing) owing to dispersal point, two averages proportionally are correlated with.Just drop on point outside the general dispersion zone and can represent potential problems in the factory.
Certainly, check that application program 40 is not limited to provide the bidimensional scatter diagram as Figure 18.In fact, check that application program 40 can provide three-dimensional or the scatter diagram of multidimensional more, these scatter diagrams have been drawn three or more SPM parameters distribution figure relative to each other.For example, Figure 19 illustrates a three-dimensional scatter diagram 210, and it has drawn three SPM parameters relation relative to each other, the especially average of three process variable relation relative to each other.
Figure 20 illustrates a four-dimensional scatter diagram matrix 220, and it illustrates four degrees of correlation between the SPM parameter.In fact, scatter diagram matrix 220 comprises 16 different bidimensional scatter diagrams, and each in these 16 scatter diagrams has all been drawn the distribution of one of four SPM parameters to another one in four SPM parameters.Here, the user still can check the degree of correlation or the mutual relationship between the different SPM parameters apace, to try hard to detect current unusual condition, perhaps predicts the unusual condition that may occur in the future in the processing factory.
Equally, the scatter diagram of Figure 18-20 and the difference of other known scatter diagram are that these scatter diagrams have drawn the average of one or more process variable, rather than process variable data point itself.Therefore, the noise that occurs in process variable is minimized usually, describes thereby obtain more level and smooth and more intelligible data.In addition, application program 40 is not limited to only draw average, but also can draw the mutual relationship between other statistical variable such as standard deviation, the intermediate value etc.In addition, application program 40 can be drawn the dissimilar statistical variables degree of correlation relative to each other, for example average and standard deviation, and the combination of statistical variable, and for example standard deviation/the average of a process variable is to the average of another process variable.As just example, application program 40 can be drawn any mathematical combination of average, standard deviation, Change in Mean, standard deviation variation or these SPM variablees of the SPM module of any one monitor procedure variable.
If desired, and as noted above usually, check that application program 40 can utilize any standard or known relatedness computation, calculate or determine the related coefficient of any a pair of SPM parameter.When related coefficient during, there is strong linear dependence (or negative linear correlation) between two SPM parameters near 1 (or-1).For one group of plural SPM variable, can determine correlation matrix, wherein each element in the correlation matrix has all defined not the related coefficient between on the same group two SPM parameters.Figure 21 illustrates the part of exemplary correlation matrix 230, and this correlation matrix 230 has the related coefficient of the average of at least 9 sensor measurements in processing factory's series loop.
According to the correlation matrix 230 of Figure 21, can determine which SPM parameter has the strongest each other degree of correlation.Significantly, the character matrix of similar Figure 21 is not easy to check.Yet application program 40 can be shown this matrix display device three-dimensional histogram, histogram 240 for example shown in Figure 22.In this three-dimensional histogram 240, can see most clearly which place is the strongest degree of correlation be positioned at.Certainly, application program 40 equally can also be with other graphics mode, line frame graph for example, and contour maps etc. show correlation matrix, all these can both show which place is the strongest degree of correlation be positioned at.
In an example, for example in the example shown in the screen display 241 of Figure 23, check that application program 40 can provide degree of correlation figure, one group of reference point under the diagram expectation process condition and the difference between one group of reference point under the current or undesirable process condition.Therefore, the screen 241 of Figure 23 comprises first degree of correlation Figure 24 2A and second degree of correlation Figure 24 2B, one group of reference point (marking) under first degree of correlation Figure 24 2A diagram expectation process condition with X, same one group of reference point under second degree of correlation Figure 24 2B diagram active procedure condition, show under the expectation process condition thus and the deviation between the parameter correlation degree under the active procedure condition, this can represent to exist in the process unusual condition.Here, be the correlation of at least two different SPM parameters of same SPM module or different SPM modules with each reference point of X mark.Certainly, as shown in figure 23,, can draw baseline mean μ and base standard difference σ for one or two process condition.
Equally, shown in the screen 243 of Figure 24, check that application program 40 can create the colour coding correlation matrix,, the value of certain relevant point is illustrated as a kind of in one group of different colours wherein according to its amplitude.A kind of like this reference point makes the easier degree of correlation of checking between the different SPM parameters of user, and detects the appearance of unusual condition in the processing factory thus, perhaps predicts the unusual condition that may occur in the future in the processing factory.Equally, should be appreciated that can be to the SPM parameter (being not only average) of other type, the mathematical combination of SPM parameter and dissimilar SPM parameters, determine and figure this correlation matrix.
Further, except above-mentioned discuss, perhaps as an alternative, application program 40 can provide other view of SPM data.As an example, application program 40 can according to the time along X-axis, the average of SPM module and standard deviation are along the form of the three-dimensional trend map of Y and Z axle; According to drawing average and standard deviation, draw the form of the 3-D histogram of quantity separately along the Z axle along X and Y-axis; According to the time along X-axis, the average of SPM module and standard deviation are along Y and Z axle, and comprise be used for average and standard deviation one or two upper control limit and the form of the three-dimensional trend map of lower control limit and/or set upper limit and regulation lower limit, visual figure or figure are provided.Certainly, the mode of visual SPM data almost is unlimited, and present disclosure is not limited to above-mentioned ad hoc approach.
Figure 25 illustrates a drawing screen 244, and it can be by checking that application program 40 generates, so that the curve that the user can more different variablees, for example the SPM parameter of the data of SPM parameter or correlated variables or the data of for example measuring and data predicted and so on.In this case, the part 245 of drawing screen 244 can make the user can select will be on the drawing part 246 of screen the specific figure line of data presented.For example, the user can select to check the figure of (equipment of selecting in the hierarchy view on same screen) measurement data, the figure of predicted data (for example data that generate by model), and the figure of residual data etc., all these figure can be in same width of cloth figure.The user can also select the drift in the execution graph to detect and/or show on drawing part 246 to measure threshold value.In the example of Figure 25, the user has selected to check the figure of the measurement data arranged side by side with predicted data (can be SPM data or original procedure variable data), so that check drift between measuring process state and the forecasting process state or inconsistent.Certainly, application program 40 can make the user can select to be plotted in together other variable and data (existing SPM data, also have process variable data), to check other relation.
As another example, check that application program 40 can produce the trend map of two (or more) different SPM parameters on same width of cloth figure, thereby make the user can check expection or the unexpected form of a SPM parameter with respect to other parameter.Figure 26 illustrates such width of cloth Figure 25 0, and wherein two SPM parameters are drawn with line 252 (relevant with valve) and 254 (relevant with transmitter).In this embodiment, user or slip-stick artist can expect regular the dispersing (divergence) of two SPM parameters, are the specific boundary of converging to of two SPM parameters then, for example with the boundary shown in vertical curve 255 and 256.Yet, before converging to this boundary, occur after the dispersing between two variablees, for example shown in the vertical curve 257 and 258, user or slip-stick artist can know existing problems, perhaps in the future unusual condition may occur.
Should believe that the degree of correlation of SPM parameter can be given factory, factory's part, total certain indication that perfects situation such as equipment.When factory's (or part of factory, or an equipment etc.) when being in normal operating state, some variable may with other variable height correlation.Along with the past of time, some correlation may change.The variation of some correlation may represent that factory is no longer to move with its previous identical performance.Therefore, examples more described below method for visualizing of providing one or more correlations how to change in time.
For the variation of checking that correlation takes place in time, can calculate correlation constantly in difference.All suc as formula 11 or the formula of formula 12 can be with the correlation that generates from the data of whole variable range.In addition, data can be divided into length-specific plurality of sections (for example, 30 minutes, 1 hour, 6 hours, 1 day, 7 days, specific number of samples, or the like), thereby can calculate one or more correlations to each section.Therefore, if correlation from one section change to next the section, this can think the variation that correlation takes place in time.As another example, can generate correlation based on the sliding window of data, described sliding window have particular length (for example, 30 minutes, 1 hour, 6 hours, 1 day, 7 days, specific number of samples, or the like).
Figure 27 is the time dependent exemplary diagram 260 of single correlation.Figure 28 is the time dependent exemplary diagram 262 of a plurality of correlations.As can be seen from Figure 28, the correlation of drawing on same width of cloth figure is many more, and it is in disorder more that figure becomes.Therefore, below use description to other illustrative methods of the relevant data of visual and a plurality of correlations.
In an example, draw the variation of correlation.For example, can draw variation from the correlation of initial value, preceding value, reference value, " normally " value, desired value etc.In this embodiment, this variation can be expressed as relative variation (for example number percent), perhaps also can be expressed as absolute change.
Usually, should calculate the reference value of given correlation according to the basic data amount, this basic data amount is as the quantity of the process variable data of the data on correlation basis based on required generation.For example, can generate mean data based on short then 5 minutes or long then 1 day data segment.It is believed that at present the correlation that utilizes at least 30 mean data points to obtain from mean data can provide statistics to go up sampling reliably.(should be appreciated that in some implementation the mean data point below 30 may provide statistics to go up reliable correlation, perhaps may need the mean data point more than 30).In this case, if be time interval of 5 minutes with the mean data point estimation, then degree of correlation window should be approximately 3 hours or longer.
In some implementation, before preserving first average, generate mean data and comprise training period.In these implementations, the algorithm that generates average comprises the baseline mean of attempting to determine this process.Can by the checking average of two coherent data pieces and standard deviation in certain tolerance each other, determine the existence of baseline mean.This has and helps guarantee that this baseline mean comes from the time period that process is in steady state (SS), rather than process is in the time period of transient state.After having determined baseline mean, this algorithm begins to calculate and provide can be by employed averages such as other algorithm, processes.These averages can be used for calculating correlation.Therefore, when with this algorithm computation first average, this process can be in steady state (SS) and be in normal operating condition.
In the example, be chosen in first correlation having determined to calculate after the reference value as the benchmark degree of correlation.As discussed above, in many cases, when calculating first correlation, this process can be in steady state (SS) and be in normal operating condition.
Yet, in some cases, if people always attempt first correlation is used as " normally " value, so problem may take place.For example, this process may be such: even under normal operating condition, the related coefficient from a related blocks to next related blocks also is erratic.If two variablees itself have the very low degree of correlation, this is especially correct so.Equally, if dispose the monitoring period of the SPM piece that generates average too high or too lowly, if perhaps when the algorithm of this average of generation is trained this process be not in normal condition, first correlation may not be the good estimation of normal value so.
Therefore, in some cases, correlation that will be different with first correlation may be useful as the benchmark correlation.In addition, for example can determine when correlation is less relatively and/or irregular, can't the selection reference correlation, perhaps select some absolute value (for example 0) as this benchmark correlation.
Below described and be used to determine whether first correlation some exemplary methods as reference value.In an example, can generate poor between first correlation and the one or more follow-up correlation, so that check whether first correlation is consistent with follow-up correlation.If first correlation and follow-up correlation differ certain degree, probably should be with first correlation as reference value.In a specific examples, first correlation and second correlation are compared.If first correlation and second correlation differ less than to a certain degree (for example 1%, 2%, 3%, 4%, 5%, 6%, 7%, or the like), first correlation can be selected as the benchmark correlation so.If difference is greater than the degree of regulation, first correlation can not be selected as the benchmark correlation so.Many other methods can be used for also determining whether first correlation should be used as reference value.
In an example, can generate reference value based on a plurality of correlations that generated (for example, these correlations are averaged, adopt the intermediate value correlation, or the like).In other example, can be based on from one or more correlations that another similar procedure generated, based on emulation, generate reference value based on model etc.
In case determined initial value, preceding value, reference value, " normally " value for each correlation, desired value etc. just can be calculated the degree of correlation and change array.Degree of correlation variation array can comprise the difference between its corresponding initial value of each correlation, reference value, " normally " value, the desired value etc.
This difference can be expressed as relative variation (for example number percent) or absolute change.Because the typical method of calculating correlation generates the correlation between 0 and 1, so absolute change also should be between 0 and 1.Yet if use number percent to change, number percent changes and may become very greatly so, especially when the benchmark degree of correlation near 0 the time.Yet,, use number percent to change of great use and/or when more desirable, may have situation when comparing with using absolute change.
Figure 29 is correlation and the reference value exemplary diagram 264 to the time.Figure 26 4 makes the user can find out correlation and the time dependent difference of reference value.Yet if when adding to more correlations and reference value among Figure 26 4, it is in disorder that this figure line may become.
Figure 30 is the exemplary demonstration 266 of the differential matrix of correlation and corresponding reference value.In this embodiment, for the correlation that is defined as not having benchmark, it is blank that matrix unit is left.Alternatively, these matrix units can be indicated with some and be filled, and these indication expressions have determined that corresponding correlation does not have benchmark.
Figure 31 is the exemplary demonstration 268 of the differential matrix of correlation and corresponding reference value.Showing in 268, the difference of correlation is being depicted as painted square, wherein the color showing difference degree of square.For example, if absolute difference less than 0.2, just gives this square first kind of color.If absolute difference greater than 0.4, just gives this square second kind of color.If absolute difference between 0.2 and 0.4, just gives this square the third color.
The demonstration 266 and 268 of Figure 30 and Figure 31 has shown the degree of correlation difference of a moment or a time period.In other example, display update can be shown the degree of correlation difference in a plurality of moments or period for allowing the user.For example, can provide user interface mechanisms (for example scroll bar, arrow button etc.), check the difference of different times or different time sections to allow the user.For example, the demonstration 268 of Figure 31 comprises navigation bar 269, to be used to show the degree of correlation difference of different moments or different times.In addition, show that 266 and 268 can comprise the user interface mechanisms that is used for " movable (animating) " demonstration, to show that how these difference are along with some moments or time period change.Equally, show that 264 also can provide similar user interface mechanisms, check the different time periods to allow the user.
In addition, can make up a plurality of degree of correlation difference value to generate the value of a plurality of correlation difference of representative.This value can be drawn in time.Can make up a plurality of degree of correlation difference value in every way.For example, one group of degree of correlation difference value can be regarded as vector, and the norm of vector can be represented the difference of relevance degree.Below provide three equatioies to be used for the norm of compute vector.Norm can be according in these equatioies any one, or different equatioies calculates.
1 norm:
(formula 13)
2 norms:
(formula 14)
Infinite norm:
(formula 15)
Δ C wherein
iBe i degree of correlation difference value, N is the number of degree of correlation difference value.If desired, can omit in the equation 13
In the factor and the equation 14
The factor.In addition, equally also can use other equation.
Figure 32 is 2-norm (equation a 14) value to the exemplary diagram 270 of time, and this 2-norm value is corresponding to a plurality of degree of correlation difference value.Figure 33 is exemplary demonstration 272, and it comprises the degree of correlation differential matrix 273 of a plurality of degree of correlation difference that are used for particular moment or time period, and the 2-norm value of a plurality of degree of correlation difference is to Figure 27 4 of time.Show that 272 can also comprise that the permission user checks different moments or the degree of correlation differential matrix 273 of time period and/or the user interface mechanisms (for example, scroll bar, button etc.) of Figure 27 4.For example, show that 272 comprise navigation bar 275.In addition, Figure 27 4 can comprise that indication is corresponding to the 4 last moments of Figure 27 of degree of correlation differential matrix 273 or the designator of time period.In addition, show that 272 can comprise user interface mechanisms,, how on some moments or time period, to change with the degree of correlation difference in the display matrix 273 to allow " activity " matrix 273.
As previously mentioned, correlation can be represented the measurement of linear dependence degree between two variablees.When one group of enterprising line linearity of data returns, determining correlation.Usually, definite " the best " match of linear regression should be organized a line of data.The result of linear regression fit usually is the Y intercept of the slope and the line of line.The slope of this line and/or this line slope over time may be in the health status of the part of monitoring factory, factory, process, an equipment, and/or to detect the unusual condition aspect be useful.As long as given two groups of data X and Y, just can come the slope of calculating optimum fit line according to following equation:
X wherein
iBe i sampling of X data set, y
iBe i sampling of Y data set, x is the average of sampling in the X data set, and y is the average of sampling in the Y data set, and N is the number of samples of each data set among data set X and the Y.
By it is plotted on the polar plot, can visual correlation and corresponding slope.Especially, the absolute value of correlation can be corresponding to utmost point footpath, and polar angle can be determined according to following formula:
θ=tan
-1M (formula 17)
Wherein m is the slope of being determined by equation 16 or other equation.The codomain of arctan function is
Therefore, use this method to have only half polar coordinates plane can comprise reference point.Selectively, in order to utilize whole polar coordinates plane, can use equation:
θ=2tan
-1M (formula 18)
In this case, the polar angle that shows on the figure can not be represented the accurate slope of this line.Yet if the user finds its visually more attracting word, this may be desirable tradeoffs.Figure 34 has shown how to draw correlation and corresponding to example of the polar angle of best-fit line slope on polar plot 276.
Figure 35 is to use the correlation of polar coordinates drafting and the exemplary demonstration 278 of polar angle.Showing that the central representation degree of correlation is near 0 in 278, and the outside represents that the degree of correlation is near 1.Therefore the point that shows in the outer shroud is the point of the high degree of correlation, and the point that shows in the center circle is the point of the minimum degree of correlation.Can ring is painted to help the different degree of correlation grade of expression.Show that 278 can also comprise user interface mechanisms (for example scroll bar, button etc.), check the figure of different moments or time period to allow the user.For example, show that 278 comprise navigation bar 279.
In another example, the difference between correlation and the benchmark may be plotted on the polar plot.In this embodiment, calculate the amplitude that the degree of correlation changes, as the absolute value of difference between correlation and its benchmark, and polar angle is simply to utilize for example correlation angle of equation 18 calculating.Therefore, will trend towards causing being positioned at the degree of correlation changing value at figure center near the correlation of their reference values.If correlation is compared with its benchmark significant variation has taken place, it will trend towards causing the degree of correlation changing value away from the figure center.Figure 36 is to use the exemplary demonstration 280 of the degree of correlation changing value of polar coordinates drafting.The ring of demonstration 280 is represented the amplitude difference of different brackets between correlation and its reference value, and can carry out coloud coding.In exemplary demonstration 280, center ring is represented the degree of correlation difference less than 0.2.Middle ring is represented less than 0.4 and more than or equal to 0.2 degree of correlation difference.Outer shroud is represented less than 0.6 and more than or equal to 0.4 degree of correlation difference.In different implementation, can use the ring of different numbers and different radiuses.Show that 280 can also comprise user interface mechanisms (for example scroll bar, button etc.), check the figure of different moments or time period to allow the user.For example, show that 280 comprise navigation bar 281.
In some cases, can in a width of cloth figure, draw correlation or the degree of correlation difference value of a plurality of moments or time period such as the polar plot of Figure 35 and 36.For example, correlation or the degree of correlation difference of different moments or time period can use line (selectively, having arrow) to connect together, and check to help the user how correlation or degree of correlation changing value change in time.
Can show with other such as the demonstration of Figure 35 and 36 to combine, to help the situation that perfects of user monitoring process.For example, Figure 23 illustrates the demonstration 241 that includes polar plot.
More than the statistics (for example average, standard deviation, Change in Mean, standard deviation variation, the degree of correlation, the degree of correlation variations, benchmark etc.) described about Figure 11-36 can be by the generation of the various device in the processing factory, for example field apparatus, I/O equipment, process controller, workstation, server, data history records device or the like.For example, average generates in the equipment at the scene, and the degree of correlation of these averages can generate in workstation.As another example, the average and the average degree of correlation generate in the equipment at the scene.
Can provide the view of some or all above-mentioned discussion to user or slip-stick artist although check application program 40, so that make the user can manually detect the existence of unusual condition in the processing factory or suspicious existence in future, but exploitation of criterion machine and executive utility 42 can also be used to automatically detecting unusual condition based on the SPM data.In Figure 37, illustrate the criterion machine exploitation of Fig. 1 and 2 and a possibility embodiment of executive utility 42 in more detail.As shown in figure 37, exploitation of criterion machine and executive utility 42 comprise it can being the criterion machine 290 based on expert's machine criterion of any kind, with one group of criterion 292, criterion can be stored in can database by criterion machine 290 visit in (for example in the storer 78B of Fig. 2).Criterion machine 290 gather or monitoring from the statistic processes monitor data (in frame 294 expressions) of the communication server 89 of the database 43 of for example Fig. 1 and Fig. 2, field apparatus, Fig. 2, data history records device etc.Certainly, these SPM data can comprise the data of any above-mentioned discussion and the data of for example obtaining by application program 38, and any other data that generate in the processing factory, have both comprised that the SPM data also comprised process variable data.In other words, criterion machine 290 can receive the data of SPM data and various other types, comprises for example process configuration data, control strategy data, control output data, process variable data, historical data, emulated data, optimization data, alarm, alarm, alarm/alarm management data, file management data, help/guidance data, rotating equipment data, lab analysis data, industrial exclusive data, environmental regulations data or the like.
In addition, criterion developing application or routine 298 make the user can be based on the statistics pattern and the degree of correlation thereof, develop one or more expert system criterions (for example as one of criterion 292), detect the unusual condition of known factory, unit, equipment, control loop etc. thus.Therefore, although expert's machine 290 used some criterion 292 at least can set in advance or be pre-configured, criterion developing application 298 makes the user create other criterion based on the experience in the monitoring processing factory.For example, if the user knows the particular combinations of SPM unusual condition or incident and represents the particular problem in the process, the user can create suitable criterion to detect this situation by usage criteria developing application 298 so, and if necessary, generate alarm or alarm based on the existence of detected this situation, perhaps take some other action.
Certainly, the run duration in processing factory, the criterion machine 290 that is configured to receive SPM data (with any other desired data) is used criterions 292, to determine whether to mate any one criterion.If detect problem in the process based on one or more criterions 292, alarm can be shown to plant operator so, perhaps send to other suitable personnel.Certainly, if desired, the various criterions that are used to detect various unusual conditions in factory and the process operation can be used as the part of expert system machine working time 290, and expert system machine working time 290 can be sought the pattern, the degree of correlation of data and SPM parameter to detect the unusual condition of exploitation.
In addition, some data that can be used by criterion machine 290 are the SPM conditions that can detect in the equipment that generates the SPM data.In this case, criterion machine 290 can be the client that reads SPM parameter and condition by for example opc server slave unit, perhaps can be the part of client.As discussed above, these SPM parameters can store into prepares against use in the future in the database, for example draw average and the standard deviation figure to the time.Under any circumstance, if the change of the average of process variable or standard deviation greater than the quantity of user's appointment, SPM module self can detect unusual condition so, for example Change in Mean, High variation or dynamically low.Next, together with all statistics monitor datas that these field apparatuss are gathered, these unusual conditions can pass to client subsequently, and for example the criterion machine 290.
Now, if factory engineering teacher or other user know, when the particular combinations of process variable changes with ad hoc fashion, should trigger specific alarm, maybe need to take specific action, so the slip-stick artist just can usage criteria definition routine 298 define a criterion detecting this situation, if this set condition, the application program of this criterion just can trigger alarm so.In an example, criterion definition application 298 can be created a configuration screen, will be stored in the one or more-criterion of (IF-THEN) type or boolean (Boolean) type so in the criteria data storehouse 292 if this configuration screen can be created the user.Figure 38 illustrates a possibility example of configuration screen 300.Especially, configuration screen 300 comprises name part 302, makes the user can be by being created the criterion define name; Condition part 304 makes the user can be criterion definition " IF " condition of IF-THEN type; With action part 306, making the user can be true time in " IF " condition of discovery, " THEN " action that definition will be taked.
In the specific examples of Figure 38, the criterion called after of being created " boiler 1 is checked (Boiler 1Check) ".In addition, as shown in figure 38, condition part 304 comprise a component from condition statement, wherein each includes equipment 310 (wherein having placed the SPM module that the used SPM data of condition statement are provided), SPM module title 312 (defining the specific SPM module in the equipment that the SPM data will be provided), SPM data type 314 (defining the data type that the SPM module is provided), relatively explain the expression of 316 (defining the mathematics comparison operation of SPM data) and value part 318 (define utilization and relatively explain 316 threshold value or the numerical value that will compare with the SPM data that received).In addition, the Boolean logic operand that frame 320 allows the user to select or definition will be used between every set condition statement, for example with (AND) operand or (OR) operand, thereby so that the mode that these conditions statements define total " IF " condition is made up in definition in logic.Although only AND and OR boolean operands are illustrated as and may select, can also provide any other boolean operands (or operand of other desired type), so that make the user can create more complicated criterion in Figure 38.In addition, one group of check box 322 and 324 can be used for the marshalling of definite condition statement.For example, select the beginning of one group of new condition statement of definition in check box 322 (before preceding half parantheses) the expression one cover parantheses, and select the end of the set condition statement of definition in check box 324 (before half parantheses in back) the expression one cover parantheses.Just as is understood, the condition statement (or condition statement group) in the different cover of combination parantheses can use the boolean operands between them to make up a condition statement of overlapping in the parantheses before.
Therefore, in the example of Figure 38, criterion is defined as: (1) is if average (the SPM module 1 by PT-101 equipment is measured) is less than or equal to 102, and standard deviation (the SPM module 3 by PT-102 equipment is measured) is more than or equal to 1.234, perhaps (2) are if the state parameter of the SPM module 2 of FT-201 equipment equals Change in Mean, and the state parameter of the SPM module 4 of FT-201 equipment equals Change in Mean, so should using action part 306 in the action of definition.
As shown in figure 38, action part 306 comprises alert name part 330, the seriousness definitional part 332 of user's appointment and describes part 334.The title that 330 definition of alert name part are associated with the alarm that generates for true time when discovery condition part 304, or give the title of this alarm, the seriousness (for example fault, maintenance, communication or other alarm types) of seriousness definitional part 332 these alarms of definition, provide the description relevant with this alarm and describe part 334, it can offer the user or the viewer of this alarm.Certainly, although the action part of Figure 38 306 has defined the alarm that will generate, but action part 306 is all right, perhaps change other action that definition will be taked into, the for example equipment in the close the plant, unit etc., switch or change the control setting in the factory, the controller in factory provides new set-point or controlled condition or the like.
Be to be understood that, after having created one group of criterion and it being stored in the criteria data storehouse 292 of Figure 37, data or unusual condition that expert's machine exploitation and executive system 42 can be returned based on the SPM module in run duration processing factory of processing factory, automatically testing process abnormality.Certainly, be to be understood that system 42 can be in constantly or periodically operation or the operation of processing factory's run duration, to detect the unusual condition in the processing factory based on the criterions in the criteria data storehouse 292.
If desired, system 42 can provide checks screen, and this screen provides the current configuration of criterion machine 290 of relevant Figure 37 and the information of state to the user.Figure 39 illustrates an example of this demonstration.Especially, the demonstration 340 of Figure 39 comprises detected ADB hierarchy 110 (as described the same with 8 about Fig. 6 at first), and about the summary of the described SPM data 115 of Fig. 8.In addition, the screen 340 of Figure 39 comprises criterion summary part 342, it list and summarized with for 290 definition of criterion machine and by some relevant information of the criterion of its execution.In the example of Figure 39, at least defined three criterions, and criterion summary part 342 provides the information about each device therefor in these three criterions, and by the alarm types or the seriousness of each generation in these three criterions.Shown in Figure 39 equally, Alert Summary part 344 provides the indication of criterion the machine 290 or any alarm that send set based on the criterion of definition thus.In the example of Figure 39, Set For Current two alarms, comprise that (System2 Failed) alarm of system's 2 faults and boiler need to safeguard (Boiler NeedsService) alarm.These alarms are not based on the criterion of special explanation is by criterion machine 290 generations of Figure 37 in the summary part 342, and still if necessary, it also can visit by rolling downwards in summary part 342.
Just as is understood, can provide available tree-like browser 110 of SPM module master and summary 115 by the method for describing about Fig. 4.Equally, utilize the configuration screen be similar to Figure 38, can create each criterion in the criterion summary part 342 by the user.And,, then show alarm if any condition and defined any criterion are complementary in the state of SPM module.Of course it is to be understood that the user can use the pre-defined criterion of known abnormality, perhaps revise existing criterion, perhaps if necessary create brand-new criterion for new situation.
Figure 40 and Figure 41 illustrate other example of the screen of criterion establishment or definition.For example, criterion definition screen 350 comprises " simply " type boolean criterion definition device, it provides set condition statement 351, wherein each condition statement all has first element 352, variable or SPM parameter that first element, 352 regulations will be tested, also comprise test or comparison condition 354 (it can be any mathematical operation or test), also have other element 356, it can be any process variable or SPM parameter.In these elements each all can manually be filled, and perhaps can select from drop-down menu if necessary.Equally, with the screen classes of Figure 38 seemingly, can specify a boolean operands, to make up each condition statement 354, and part 360 can be used for specifying alert name, seriousness and as the message that will offer the user of an alarm part, if the IF of definition is expressed as really talk about as a result.
Figure 41 illustrates more the criterion definition device 370 of " senior " type, and it comprises the IF part 372 that can construct by the selection of different buttons 374.Button 374 can comprise or allow user's specified type or special parameter (ADB parameter for example, SPM parameter, process variable (PV) state or parameter etc.), boolean operands, in part 372, create numeral and mathematics statement of equal value that more complicated IF statement will be used.Comprise alert name definitional part, seriousness definitional part and message part in interior part 376, can be used for defining will be by the alarm or the alarm of this criterion generation.Certainly, any alternate manner that application program 40 can provide definition will be carried out criterion by criterion machine 290 is to detect unusual condition current or prediction.
In addition, although the screen of Figure 38, Figure 40 and Figure 41 can be used for making the user can define boolean's criterion of IF-THEN type, can also define the criterion of other type additionally or alternati.For example, can revise the screen of Figure 38, Figure 40 and Figure 41, perhaps can provide other screen criterion (for example, to be similar to by Microsoft to allow definition spreadsheet type
Those criterions that spreadsheet software provides), the mathematical relation between fuzzy logic criterion, the parameter, degree of correlation generation, parametric filtering (for example low-pass filtering, high-pass filtering, bandpass filtering, finite impulse response (FIR) (FIR) filtering, infinite impulse response (IIR) filtering etc.) or the like.
During operation, the criterion machine 290 of Figure 37 can use many diverse ways to mate the criterion of definition in the condition of SPM module and the criteria data storehouse 292.If the criterion in the criteria data storehouse 292 is too complicated, criterion machine 290 can be programmed with suitable logical processor simply so.Yet very complicated if some criterion becomes, it is useful using the expert system tool of having developed.
Start in case should be appreciated that monitor procedure, all criterions will be fed in the criterion machine 292 by any suitable interface.After this, when the SPM condition changes, for example can be detected by the frame 132 or 134 of Fig. 4, just these conditions are fed in the criterion machine 292.In each time interval, criterion machine 292 determines whether to mate the condition of arbitrary criterion.If satisfy arbitrary criterion, then criterion machine 292 sends back to primary application program with notice, thereby can show alarm to the user, perhaps based on the action statement of satisfying specified criteria, takes some other action.
Exemplary screen displays 380 and alarm that Figure 42 illustrates processing factory's part show 382.If satisfy one or more suitable criterions, criterion machine 292 can make alarm show that 382 show so.Alarm shows 382 can comprise the corrective action of suggestion, to the link of factory's program, to link of checking the performance/quality data or the like.Screen display 830 can also comprise show the equipment relevant, loop, measurement etc. with this alarm the display part on every side highlight part 383.For instance, criterion machine 290 can be to checking that application program 40 sends data, thereby make its display alarm show 382 and highlight part 383.
Figure 43 illustrates another exemplary screen displays 384 of processing factory's part, and this demonstration 384 comprises alarm/warning information.Especially, Figure 38 5 has shown the various statistical parameters relevant with this alarm/alarm.Screen display 384 can also comprise the messagewindow 386 and 387 that shows with this alarm relevant information.Messagewindow 386 and 387 for example by coloud coding, can show different importance rates.If satisfy one or more suitable criterions, criterion machine 290 can make window 385,386 and 387 show.For instance, criterion machine 290 can be to checking that application program 40 sends data, thereby make its display window 385,386 and 387.
Figure 44 illustrates the another exemplary screen displays 390 of processing factory's part, and this demonstration 390 comprises alarm/warning information.Figure 45 illustrates an exemplary screen displays 395 again of processing factory's part, and this demonstration 395 comprises alarm/warning information.
Although above criterion machine 292 is described, additionally or alternatively can also use the analytical engine of other type.The example of operable other type analysis machine comprises that the mathematical computations system is (for example, from Wolfram Research's
Computing system is from MathWorks's
System etc.), fuzzy logic analysis machine, pattern matching machine, neural network, regretional analysis machine or the like.
Although above-mentioned data acquisition technology, visualization technique and criterion machine technology can be used in the factory-configured of Fig. 1 gathering, checking the data with treatment S PM, it equally also can be used for other configuration.For example, it can be used for the environment (for example DeltaV, AMS and Ovation) based on PC, wherein software conducts interviews to various servers (for example opc server, web server etc.), so that obtain plant hierarchy, and search equipment in the given factory and the equipment of determining to have ADB and SPM function.The another kind of use is to be directly used in cured in situ equipment, and in gentle Si Mangte Rosemount3420 equipment, it has built-in opc server, and can directly conduct interviews to field apparatus.In this case, equipment self can be stored data acquisition and criterion machine application program, and moves these application programs and platform that need not be independent, as the teller work station.In addition, under this situation or other situation, visualization applications described herein or parts can move on miscellaneous equipment or carry out, portable equipment for example, personal digital assistant etc., they can be connected to stand-alone device, the SPM data of being gathered to obtain, alarm etc. are checked for the user.
Similarly, data acquisition and check that application program can be by long-range device access field apparatus or the miscellaneous equipment checked.Therefore, this software can reside in the web server, perhaps can conduct interviews by the web server, and the web server for example is assets inlet and the AMSweb (Asset Portal and AMSweb) that is provided by Emerson process management company.And although opc server has been illustrated as in Fig. 2 and comprises the SPM module and separate at interior field apparatus, opc server or other server also can be arranged in self of one or more field apparatuss.Equally, the data collection application 38 of unusual condition prevention system and criterion machine 42 can be positioned at and ADB and/or the same equipment of SPM module, and these ADB and/or SPM module generate the SPM data of the field apparatus that for example wherein has ADB and/or SPM module.In this case, need not OPC interface (although still may use the OPC interface), unusual condition prevention system 35 just can with the same equipment of statistical data collection module in operation or carry out.If desired, the SPM data that generated by application program 38 and 42 or alarm, alarm etc. can conduct interviews according to any way from the field apparatus visit data usually, for example by controller connect, by portable equipment, by wireless mode or the like.
Figure 46 illustrates is not needing to use distributed director, main frame or other more conventional user interface to support in the processing factory of SPM module and unusual condition prophylactic function, realizes the another kind of mode of unusual condition prevention.In the system 400 of Figure 46, some or all unusual condition prophylactic applications programs 35 and/or application program 38-42 can be stored on the equipment except that host work station or personal computer.The example system 400 of Figure 46 comprises that the one group of field apparatus 405 that is connected to interfacing equipment 410 (is illustrated as the Fieldbus field apparatus, but they can also be the equipment of other type), interfacing equipment 410 for example can be gentle Si Mangte Rosemount3420 equipment.In this case, not the interfacing equipment 410 of personal computer, can comprise some or all functions of above-mentioned unusual condition prevention system 35.Especially, interfacing equipment 410 can comprise browser 412, the data that browser 412 receives and organizes field apparatus 405 (can be various dissimilar field apparatuss) to be transmitted.If desired, this browser or communication facilities 412 can comprise the OPC browser.Data collection application 38 (or its part) also can be stored in the processor of interfacing equipment 410, and on the processor of interfacing equipment 410, carry out, to gather data, comprise the SPM data of the above-mentioned any field apparatus that has the SPM module from field apparatus 405.In addition, as discussed above, interfacing equipment 410 can comprise one or more SPM modules 414, so that directly from one or more field apparatuss (field apparatus that does not for example comprise SPM module or function) gatherer process variable data, and generates the SPM parameter.By this way, the SPM module 414 of storage and execution can compensate the disappearance of SPM module in some field apparatus 405 in interfacing equipment 410, and can be used for providing SPM data for the field apparatus of self not supporting SPM module or SPM function.
In addition, criterion machine application program 42 (or its part, for example criterion machine 290 of Figure 37) can be stored in the interfacing equipment 410 and by its execution, and database 43 equally also can be arranged in interfacing equipment 410.Interfacing equipment 410 can connect by hard wire, 2-line for example, 3-line, connection such as 4-line communicates with miscellaneous equipment such as host work station 430, thereby provide SPM data or the data by its exploitation to these equipment, for example alarm, data plot etc. are so that checked by the user.In addition, as shown in figure 46, interfacing equipment 410 can connect via one or more radio communications, is connected to web browser 440 and is connected to the hand-held computing equipment, for example phone, personal digital assistant (PDA), laptop computer etc.In this embodiment, the one or more application programs 40 of checking can be in the miscellaneous equipment such as host work station 430, in web browser 440 or storage and execution in hand-held computing equipment 450, and these application programs can communicate with interfacing equipment 410, thereby obtain desired data, so that to handle as any way of above-mentioned either party's formula and to check.If desired, equipment 430,440 and 450 can comprise the criterion definition application 298 of Figure 37, will be by the criterion of the execution of the criterion machine in the interfacing equipment 410 so that the user can be generated.Equally, as shown in figure 46, can pass through web browser 640 from main frame 430 dereferences, and offer other user via any desired web connection from the data of interfacing equipment 410.Certainly, interfacing equipment 410 can comprise the web server, and can use any desired agreement, and for example OPC, Modbus, Ethernet, HTML, XML etc. communicate with any miscellaneous equipment such as equipment 430,440,450 and 460.
Figure 47 illustrates another process plant configuration 500, wherein may the interfacing equipment 410 similar or identical with the interfacing equipment of Figure 46, be connected between one group of field apparatus 510 (constituting the part of heat exchanger 515) and the Process Control System 520.Here, interfacing equipment 410 can comprise all application programs and the function of the equipment 410 of Figure 46, the data that can be provided for checking to main frame 530, and can provide alarm or the alarm that generates by the criterion machine to controller system 520.Controller system 520 can be incorporated into these alarms or alarm and the alarm alarmed with other controller type, so that checked by for example control operation person at operator workstation 540 places.Certainly, if desired, host work station 530 can comprise any desired application program of checking, so that to comprise any required mode of arbitrary mode discussed herein, checks in interfacing equipment 410 data of gathering or being provided by interfacing equipment 410.Equally, these data can be checked by web browser 550 by other user.Therefore, should be appreciated that the various application programs of being correlated with unusual condition prevention system 35 discussed herein can be distributed in the different equipment, and do not need in having the equipment of user interface, to operate all.On the contrary, data (such as the SPM data) can gather in such as an equipment of interfacing equipment 410 and handle, and send, so that check in diverse equipment.Equally, criterion can be created in the user interface facilities such as main frame, web browser, PDA etc., and sends to the distinct device such as interfacing equipment 410, so that carry out in the criterion machine.
Although in the example of Fig. 1 and Fig. 2, will the application program 38,40 and 42 relevant be illustrated as and be stored on same workstation or the computing machine, but some or other entity in these application programs also can be stored in processing factory 10 or in other associated workstation or the computer equipment and be carried out with unusual condition prevention system 35.In addition, the application program in the unusual condition prevention system 35 can be decomposed, and carries out on two or more computing machines or machine, and can be configured to connect the co-operate of pulling together each other by wired, wireless and/or intermittent communication.Further, unusual condition prevention system 35 as described herein can comprise any or all in application program 38,40 and 42, and can comprise but must not comprise ADB as described herein or SPM module.In addition, although example as described herein uses the SPM module of Fieldbus SPM modular form, but employed here term " SPM module " intention is meant and comprises the statistic processes monitoring module, routine of any other type etc., their gatherer process data or variablees, and carry out some statistical operation or monitoring, and no matter whether these modules or routine meet known Fieldbus agreement.
In addition, although above description relates to some modules such as ADB module and SPM module of counting statistics data, also can use the signal Processing data acquisition module of other type of the signal Processing data that can generate other type.For example, can generated frequency analyze data (for example data that generate based on some other conversion of Fourier transform or process variable), autoregression data, wavelet data, utilize data that neural network generates, utilize the signal Processing data acquisition module of data that fuzzy logic generates etc., also can be used for the unusual condition prevention system.Therefore, the monitoring module that term used herein " signal Processing data acquisition module " intention is meant and comprises any kind, software routines, hardware etc., their gatherer process data or variablees, and carry out some signal processing operations or monitoring, for example generate statistics, the mathematic(al) manipulation process data (for example, use Fourier transform, discrete Fourier transform (DFT), fast fourier transform, short time discrete Fourier transform, transform, Hilbert transform, the Radon conversion, the Wigner conversion, wavelet transformation etc.), information extraction from the process data of conversion, fuzzy logic is used in filtering, neural network, information extractions from process data such as autoregression technology.
Further, although described some examples, in these examples Collection and analysis from the signal Processing data of the signal data acquisition module in the single processing factory, be to be understood that similar techniques also can be used for the situation of a plurality of processing factories.For example, can collect, these data can be offered analytical engine then and/or check application program from the signal Processing data of a plurality of processing factories.
Although described the example that uses special communication protocol and technology, also can use various other agreements and technology, comprise being used to visit from the configuration data of signal Processing data acquisition module and the known protocol and the technology of signal Processing data.For example, other agreement except OPC and technology can be used for discerning and/or configuration signal deal with data acquisition module, collect signal Processing data or the like.Other technology can comprise, for example uses Internet Protocol, Ethernet, XML, proprietary protocol etc., and other implementation can use web server and/or dedicated computing equipment, for example process controller, I/O equipment, workstation, field apparatus etc.Similarly, also can use and comprise the hierarchical structured data of proprietary data in other interior type.
Although the unusual condition prevention system with the relevant application program of unusual condition prevention system described herein, preferably in software, implement, but they also can be implemented in hardware, firmware etc., and can be implemented by other any processor relevant with Process Control System.Therefore, element as described herein can be implemented in the multi-usage CPU of standard, perhaps implements on needed custom-designed hardware or firmware, for example special IC (ASIC) or other hardwired device.When implementing in software, software routine can be stored in any computer-readable memory, for example disk, laser disk (for example DVD) or other storage medium, the RAM of computing machine or processor or ROM, any database or the like.Equally, this software can send user or processing factory to via any transfer approach known or expectation, for example, by computer readable diskette or other Computer Storage mechanism movably, perhaps by such as communication channels such as telephone wire, the Internet (these all be considered with this software is provided via movable storage medium be identical or interchangeable).
Therefore, although the disclosure is described according to concrete example, but, these examples only are exemplary, rather than restrictive, for the person of ordinary skill of the art, under the premise without departing from the spirit and scope of the present invention, can disclosed embodiment be changed, it is conspicuous adding or deleting.
Claims (24)
1, a kind of method that is used to detect the unusual condition relevant with processing factory, this method comprises:
The signal Processing data that the signal Processing data collection module that reception is realized by at least two equipment relevant with described processing factory is produced;
Provide configuration data to analytical engine disposing described analytical engine, thereby at least based on the described signal Processing Data Detection at least a unusual condition relevant with described processing factory;
Provide described signal Processing data to described analytical engine; And
Use described analytical engine to determine whether and taking measures;
Wherein the received signal deal with data comprises the statistics that a plurality of statistic gathering modules that reception is realized by a plurality of field apparatuss are produced; And
Wherein providing described signal Processing data to comprise to described analytical engine provides statistics that described a plurality of statistic gathering module produced to described analytical engine;
Wherein use described analytical engine to comprise and use described statistics to determine whether and taking measures.
2,, further comprise from the described statistics of database retrieval according to the method for claim 1.
3, according to the process of claim 1 wherein that described statistics comprises the statistical parameter relevant with process variable.
4, according to the process of claim 1 wherein that described statistics comprises the situation indication of the statistical parameter relevant with process variable.
5, according to the process of claim 1 wherein that the received signal deal with data comprises that further receive frequency analyzes data, autoregression data, wavelet data, utilizes the data that neural network produces and use in the data that fuzzy logic produces at least one.
6, according to the process of claim 1 wherein that the received signal deal with data further comprises the signal Processing data that reception is produced by at least one the signal Processing data collection module of at least one realization in process controller, data history records device and the workstation.
7, according to the method for claim 1, wherein the received signal deal with data comprises the data that reception is produced by field apparatus, and this field apparatus is deferred at least one in basic Fieldbus agreement, HART agreement, Profibus agreement, WORLDFIP agreement, Device-Net agreement, AS-Interface agreement and the CAN agreement.
8, according to the process of claim 1 wherein that the received signal deal with data comprises by at least a received signal deal with data in cable network and the wireless network.
9, according to the process of claim 1 wherein that the received signal deal with data comprises by at least a received signal deal with data in wired connection and the wireless connections.
10, connect the received signal deal with data according to the process of claim 1 wherein that the received signal deal with data comprises by intermittence.
11, according to the process of claim 1 wherein that providing described signal Processing data to comprise to described analytical engine provides the signal Processing data to the criterion machine.
12, according to the method for claim 11, wherein provide the signal Processing data to comprise to described criterion machine, provide the signal Processing data to the criterion machine that is configured to use at least one boolean's criterion at least some in the described signal Processing data.
13, according to the method for claim 11, wherein provide the signal Processing data to comprise to described criterion machine, provide the signal Processing data to being configured to use at least one fuzzy logic criterion at least some criterion machine in the described signal Processing data.
14, provide described signal Processing data to comprise according to the process of claim 1 wherein, provide the signal Processing data to the analytical engine that is configured to determine the degree of correlation of at least some in the described signal Processing data to described analytical engine.
15, according to the method for claim 1, wherein provide described signal Processing data to comprise, provide described signal Processing data in neural network, mathematical machine, fuzzy logic analysis machine, images match machine and the regretional analysis machine at least one to described analytical engine.
16, according to the process of claim 1 wherein that using described analytical engine to comprise uses described analytical engine to determine whether producing warning or alarm;
This method further comprises described warning of generation or alarm.
17, according to the process of claim 1 wherein that using described analytical engine to comprise uses described analytical engine to determine whether changing the control setting relevant with described processing factory;
This method further comprises impels described control setting to change.
18, use described analytical engine to comprise to use described analytical engine to determine whether and come prompting operation person to consider unusual condition with one or more recommendation measures according to the process of claim 1 wherein;
This method further comprises impelling with described one or more recommendation measures points out described operator.
19, according to the process of claim 1 wherein that using described analytical engine to comprise uses described analytical engine to determine whether changing controlled condition relevant with controller and set-point;
This method further comprises impels the controlled condition relevant with described controller and at least one change in the set-point.
20,, further comprise the information that the state of the described analytical engine of expression during analyzing described signal Processing data is provided by user interface according to the method for claim 1.
21,, further comprise the information that the configuration of the described analytical engine of expression during analyzing described signal Processing data is provided by user interface according to the method for claim 1.
22, method according to claim 1, wherein provide configuration data to described analytical engine comprise provide configuration data to described analytical engine disposing described analytical engine, thereby further based on the process configuration data, the control strategy data, the control output data, process variable data, historical data, simulated data, optimize data, warning, alarm, the alert/alarm management data, the document management data, help/vectoring information, rotating equipment data, in lab analysis data and the environmental regulations data at least one detects at least one unusual condition relevant with described processing factory.
23, a kind of system that is used to detect the unusual condition relevant with processing factory, this system comprises:
Receiving trap is used for the signal Processing data that produced by the signal Processing data collection module that the network reception is realized by at least two equipment relevant with described processing factory;
Generator, be used to provide configuration data to analytical engine disposing described analytical engine, thereby detect at least a unusual condition relevant with described processing factory; And
Realize the device of analytical engine, thereby be used for realizing whether at least some decisions of being analyzed described signal Processing data by analytical engine should take measures;
Wherein said receiving trap is used to receive the statistics that a plurality of statistic gathering modules of being realized by a plurality of field apparatuss are produced; And
Wherein said generator is used to provide statistics that described a plurality of statistic gathering module produced to described analytical engine;
The device of wherein said realization analytical engine is used to use described statistics to determine whether and taking measures.
24,23 system as requested, the device of wherein said realization analytical engine be used for analytic process configuration data, control strategy data, control output data, process variable data, historical data, simulated data, optimization data, warning, alarm, alert/alarm management data, document management data, help/vectoring information, rotating equipment data, lab analysis data and environmental regulations data at least one whether should take described measure with decision.
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| CN105652854B (en) * | 2009-12-09 | 2019-06-04 | 比特有限责任公司 | Automated management system and method |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN1926489B (en) | 2012-02-15 |
| CN1926487A (en) | 2007-03-07 |
| CN1926489A (en) | 2007-03-07 |
| CN1926488A (en) | 2007-03-07 |
| CN100582978C (en) | 2010-01-20 |
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