FI130063B - Parametrizable IO module - Google Patents

Abstract

An IO module (401) for an automation system, the IO module (401) comprising a microprocessor (406) configured to communicate with IO channel modules and an IO bus switch where the microprocessor is configured to run parametrizable logic, wherein an output (1602) is controllable to a certain state when one input or a combination of inputs (1601) change to a predefined state.

Description

Parametrizable 10 module

Field

The invention relates to 10 modules in an automation system with process automation industry.

Background

In a process plant an automation system controls various quantities such as pressure, temperature, flow rate and levels. The automation system gets measurements from different probes and sets control values for different field devices. All these are connected together using different networking components.

Typically, the automation system of large industrial facilities is built with hierarchical model. This hierarchy is described in ISA-95 standard. The automation system manages the operations in levels 0-2. The level 1 comprises of the actual process devices that fare sensors and actuator. These are connected with different device networks to 10 modules. The modules are managed by 10 substations which operate by the commands coming from controllers. The controllers run the automation applications that are designed for the process.

There are different kinds of field devices and a lot of different connection possibilities for them. Traditionally the field devices have been

N connected with standard 4-20mA signal, but new bus networks and Ethernet

N based networks have emerged. Different networks reguire different cabling and 2 different connectors. The 10 modules must be designed so that they can match

N 25 these different networks. This requires a lot of different 10 modules and flexible

E 10 substation to carry the modules. 2 One typical issue with the process automation system is the slow o default control cycle. In process industry 500ms control cycle has been a norm.

N During this process cycle the measurement device has provided information through an 10 module to the process controller and the process controller has 1 commanded an 10 module to activate an actuator for change. However, there are many applications that require faster process cycles than 500ms. These applications may relate to safety, machine condition or other topics. With these topics there are typically moving objects that must be stop before anything critical happens. Time limits for such issues are typically in the scale of milliseconds to tens of milliseconds. Typically, these fast control actions are done with separate 10 structures with configurable local control. Safety control systems are good example of these.

There have been also faster process control cycles down to tens of milliseconds, but since there are much higher device and cost requirement related, the faster cycles are mostly avoided.

All the aforementioned problems together make a great need for solution that solves high level control 10 and local fast control needs.

The US 2013290496 A1 describes a configurable connectorized system for providing supervisory and distributed control.

The US 2006155900 A1 shows a system for making interconnections between input and output modules.

The EP 2511778 A2 describes an input module for an industrial controller to simplify setup and commissioning.

Brief description

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O The present invention seeks to provide a parametrizable 10 module as

Tr described in claim 1 and arrangement as described in claim 5. Additionally, the

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N 25 presentinvention describes method as described in claim 8. x 2 © = List of drawings 00

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Example embodiments of the present invention are described below, by way of example only, with reference to the accompanying drawings, in which 2

Figure 1 shows an overview of an automation system;

Figure 2 shows modular approach of controller groups; and

Figure 3 shows modular approach of 10 unit; and

Figure 4 shows the software architecture model; and

Figure 5 shows the allocation of software functions; and

Figure 6 shows logic execution by 10 subsystem; and

Figure 7 shows one preferred embodiment; and

Figure 8 shows another preferred embodiment; and

Figure 9 shows another preferred embodiment; and

Figure 10 shows another preferred embodiment.

N Description of embodiments

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O Figure 1 is an overall view of prior-art modern automation system.

N 25 The automation system comprises of field devices 1 and 10 systems 2 that are

E connected via cabling into controllers 6. The cabling can be direct cabling 3, hub- a © spoke type of network 4 or ring network 5. The controllers are connected to = system bus 7, that can be redundant. Operator stations 8, history databases 9 and

S configuration servers 10 can be attached to the same network. A firewall 11 can be used to protect the system bus from other networks 12. Maintenance, ERP, 3 configuration and simulation servers 13 can be in these networks. Additional firewall 14 can be used for connection to further networks 15.

Figure 2 describes modular Controller group 104 and modular 10 units 301. Controller group is equipped with integrated network switch module 302 that can be single or redundant. Other modules comprise Controller modules 303 and interface modules 304. The benefit of this approach is that the amount of

Controller modules is not tied with number of interface modules and the amount can be adapted to actual needs case by case. Each interface module contains interfaces for 10 poles 101, standard field buses 305, e.g. PROFIBUS or serial interfaces, e.g. RS-232, RS-485. By introducing more interface modules to

Controller group, the more 10 poles or field buses can be controlled. 10 poles contain 10 units which contain single 10 channel modules. 10 unit can be basic 10 units, 10 units complying functional safety, ATEX compliant units, machine condition monitoring (MCM) units or mains voltage tolerant 10 units. Benefit of this approach is that 10 channel amount, type and mix can be altered with minimum effort.

Figure 3 describes an embodiment of 10 unit on 10 pole. 10 unit comprises 10 module 401, 10 channel modules 402 and 1O termination module 404. 10 termination module acts as base module for other modules. 10 module comprises a microprocessor 406 for communication with 10 channel modules and 10 bus switch 403 for Ethernet communication. 10 channel module comprises microprocessor for 10 control, fail safe functions, field loop 407 fault monitoring

N and communication purposes to 10 module. 10 channel module comprises also

N function for indicating whether it has been taken into use i.e. configured or not. = 25 The communication purposes may be e.g. Highway Addressable Remote

N Transducer (HART) communication. Field equipment electrical control is

E performed by the 10 channel module. 10 units are connected to 10 bus 405 for = data exchange with Controller Interface modules. In order to enable possibility to e replace or change 10 module online, the 10 bus switch is separated from 10

N 30 module. Due module breaks on control systems, online changes are needed with minimum impact to other areas of the system. The 10 bus is Ethernet based 4 communication. Any suitable protocol can be used on top of physical IEEE 802.3 infrastructure.

Figure 4 shows software model. Controller applications software functions are divided to multiple modular layers. Each layer can be allocated independently to automation platform and can be independently redundant. Controller 1211 functions include at least execution logic 1203, related external connections 1202 and 10 connections 1201. External connections include functions such as data communication between other controllers, user interface connections and connections to history services. 10 connections include connection 10 interface data. 10 connections are purely name based to allow late 10 allocation and flexible changes of 10 channel types. It is typical that 10 type of connection may change from wired 10 to link 10 e.g.

MODBUS 10 from PLC or vice versa. 10 interface 1212 is standardized way to connect to any 10. It provides name based data interface to 10, standard field buses e.g. PROFIBUS, PROFINET or links e.g. MODBUS interfaces. 10 interface has

IO specific logic 1204 including 10 channel or 10 bus parametrization, data interface to 10 modules 1205 or to field buses and fail-safe logic if connection to controller is lost and some fail safe actions are required e.g. close valves, stop motors. 10 module 1213 manages set of 10 channel modules 1214. It manages 10 channel connections 1207 from 10 interfaces to 10 modules read/write process data and read diagnostics data. 10 channel logic 1206 normalizes 10 data if not done by 10 channel module and may have additional parametrizable logic. 10

N channel module 1214 handles 10 signal conditioning logic 1208. This logic

N contains e.g. conversion of analog input AD-converter 0-20mA measurement to = 25 standardized 10 data e.g. value 0-65536. 10 channel module typically handles

N calibration data related to analog measurements or outputs. Field connections

E 1209 connect 10 channel module measurement and output signals to field sensors 2 and actuators

Figure 5 shows allocation options of software functions. Typical rule is

N 30 that when 10 size i.e. number of 10 behind one controller, grows, centralized solution with high capacity platform for controller and 10 interface is cost- 5 effective solution when calculating cost per 10 channel. This solution has drawback that in failure cases affected process area is larger due to higher number of affected 10 channels. When 10 size is smaller it is more feasible to allocate control and 10 functions closer to 10 channels. Distributed control function allocation enables partial testing of system. It is typical that in control application development, work is distributed to teams located in wide area. If application involves specific equipment, testing can be done with laptop and one module with embedded controller and 10 interface functionality. In cabinet manufacturing allocation of controller and 10 interface to 10 poles enables testing 10 of field connection without installing separate controller group. Separate controller 502 and 10 interface 202 in controller group provide best consistent control capacity. 10 interface is connected to 10 pole via 10 pole connector 1301 and 10 bus connects to 10 units 301. Controller function and 10 interface function have dedicated hardware.

When 10 interface hardware has sufficient capacity to run control E and 10 interface F functions these both functions G can be run inside 10 interface hardware. If control function is secondary e.g. lighting control or air ventilation control functionality can be reasonably run in virtualization platform 107. Virtual controller I and virtual 10 interface ] provide combined control functionality H.

When IO size is small e.g. remote 10 or in manufacturing controller and 10 interface functionality can be located to IO pole 1301 connector including

Ethernet switch and microprocessor. Combined functionality marked as K. In

N minimal case controller and IO interface functionality can be allocated to IO

N module L. Allocating functionality near 10 channels is also key to fastest 10 loops. = 25 This minimizes communication delays between 10 channel and controller

N functionality.

E Figure 6 describes logic execution by 10 subsystem. The 10 module = 401 may include microprocessor 406 that is capable of running some or all parts e of the controller 502 code. If the microprocessor is powerful enough the 10

N 30 module may run all of the application needed by it to accomplish the needed automation task. There are two benefits from this approach. One is that the actual 6 controller is not needed. This kind of solution is very beneficial for very small automation installations due to reduced space needed. At the same time the reliability increases since the critical communication paths to controller are not needed. Another benefit is that the 10 module can run faster applications due to thereduced need of communication time.

If the microprocessor 406 is not powerful, it can manage only light tasks and cannot run the whole application. In these cases, the microprocessor may run protective logics or simple control logics. In most cases the parametrizable logic is very simple: output 1602 must be controlled to certain state when one input or combination inputs 1601 change predefined state. The inputs are directly accessible 1603 by the microprocessor 406. 10 module can execute such logic very fast, because inputs are scanned continuously. One can add parameters to logic to indicate which input changes need to be monitored and how these changes should control the outputs. As 10 module runs this simple logic, reaction to change of input can be very fast.

The 10 module that provides this functionality is called parametrizable 10 module. This kind of device is highly beneficial. One physical 10 module with common connections can manage both; slow higher-level process automation and local parametrizable fast actions. The normal control operation from remote controllers is maintained as such, but additional fast control or safety procedures are provided locally.

Using parametrizable 10 module removes the need of having more

N computing capacity in the 10 modules or enables having less 10 modules to run

N same tasks. Simultaneously the need of faster buses is reduced. Additional benefit = 25 is the independence of the local 10 operation. If any malfunction occurs to the

N communication lines between the parametrizable IO module and the controllers

E the reguired fast control action is not affected. = The configuration of parametrizable 10 module is done through 2 automation system configuration software. The software provides user interface

N 30 for configuring the parameters of 10 module. There are different simple logic operators that can be used to configure the parametrizable 10 module. Typical 7 logic operators are such as, but not limited to: AND, OR, NOT, value comparisons, counters and value holders. Additionally, some arithmetic operators can be used.

The values from local parametrized operators can be forwarded to the controllers and further processed there.

One example of preferred use for parametrizable 10 module for controlling motorized valve is shown in Fig 7. There can be enormous power turning the valve and if the valve is closed and the same turning power is applied, defects are very probable. The parameterized 10 module can be used to safeguard the motor by using same signals that are normally used for measurement and control by upper level controllers 502. No additional devices or cabling is needed.

The controller can provide commands such as “close” 1708 - “open” 1709 - “brake” 1710. The 10 module forwards these commands to outputs 1705, 1706, 1707 only if related sensors are in correct state. E.g. when the controller commands “close” the 10 module checks if the signals “Limit close” 1701 and “Torque, close” 1702 are not active. If either of those is active during the movement, the 10 module immediately ceases the movement. This happens before the controller reacts to the “Limit close” 1712 or “Torque, close” 1713 signals. In the next control cycle the controller acts accordingly. However, the parametrizable 10 module has already managed the critical situation. Similar procedure can also be parametrized to "open" command with “limit open” 1703 and “torque, open” 1704 signals.

Another example of preferred use for parametrizable 10 module for

N controlling valve is shown in Fig 8. There can be cases where stopping the filling

N of some tank must be done in all circumstances. With such cases all additional = 25 steps that are unneeded must be avoided. Using parametrizable 10 module with

N input information about level 1801 of the tank that is normally provided as input

E 1804 to the controller can be used to stop the filling of the tank when = parametrized value is reached even if the level signal never reaches the e controller. In normal operation the controller can be used to directly command

N 30 the output 1803 to control the valve with the same 10 1802. 8

Another example of preferred use for parametrizable 10 module for controlling blade is shown in Fig 9. The flowing pulp web traverses fast (1-5 m/s).

Cutting the pulp to be baled must be done in very strict timeframe to provide accurate sized pulp sheets. The normal process control cycle time is far too slow for this kind of operation. Adding a digital input with the information about pulp web edge 1901 the 10 subsystem can detect 1906 the edge and use accurate parametrized counter timer 1904 to calculate the output 1902 of blade control.

However, the digital input 1903 from the process controller mandates whether it activates the blade or not. This way fast parts of the process can be controlled with the same 10 devices as slower parts. The input signal 1901can also be held 1711 stable for data input 1905 for the controller.

Another example of preferred use for parametrizable 10 module for machine condition monitoring is shown in Fig 10.

In machine condition monitoring applications fast signals, like signals from vibration sensors are used as inputs and characteristic values are calculated from input signal and these values may be used in control logic to safeguard the machine. When sufficient microprocessor is used in parametrizable 10 module, such characteristic values can be calculated in the IO module and use these values as part of safeguarding logic executed in the IO module.

There can be upper level machine condition monitoring application to follow long term condition of filed devices. This application is typically run on separate computer or dedicated controller connected to automation system 10

N bus. The upper level long term condition monitoring tries to reveal malfunctions

N that are detectable by trends. However, the same signals, like signals from = 25 vibration sensors that are used for long term monitoring can also be used for

N revealing immediate malfunction of devices. The revealing issue can be for

E example a high sporadic vibration. This can be detected by calculating 1913 some = characteristic from incoming signal 1910. This calculation may provide peak e values, root mean sguare (RMS) 1914 or other similar value. The parameters

N 30 needed for the calculation, such as time span, may be parametrized. These calculated values can be compared to parametrizable limit values that mandate 9 the logic to stop the device. The output 1911 of the logic overcome the actual command 1915 from the controller. This kind of safeguarding logic bring additional benefits by shutting down critically malfunctioning devices by stopping the motors running them and possibly releasing some brake functionality as soon as possible and thus avoiding further defects.

Additionally, the parametrizable 10 module can be used to provide fast human input to the subsystem. This kind of input lags too much if normal 500ms control cycle is used to react to human pressing of control buttons. This can be e.g. control of the paper web cutter where the human input must be reacted rapidly. Using parametrizable 10 module enables controlling common actuator by direct human input and control system input.

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Claims (3)

Claims

1. An 10 module (401) for an automation system, the 10 module comprising a microprocessor (406) configured to communicate with 10 channel modules (402) and an 10 bus switch (403) where the microprocessor is configured to run parametrizable logic, wherein an output (1602) is controllable to a certain state when one input or a combination of inputs (1601) change to a predefined state characterized in that the 10 module is configured to run a machine condition monitoring application by calculating characteristics values on the basis of input signals (1910) from vibration sensors and using the characteristic values to safeguard a machine, wherein the 10 module is configured to simultaneously transmit at least some of the input data (1601) to controller (502) and receive control commands (1605) from controller.

2. An arrangement for fast control of critical task with automation system 10 module (401) having a microprocessor (406), where the microprocessor is configured to run parametrized logic and the 10 module is part of 10 unit (301) that comprise also of single 10 channel modules (402) and 10 termination module (404) that acts N as base module for other modules and where the 10 module is O connected via Ethernet network with at least one controller (502) O that can receive input data from 10 module and/or transmit N 25 commands to 10 module, characterized by that there are vibration E sensors connected to 10 channel modules (402) providing input © signal (1910) to the 10 module (401) for local calculation of = machine condition monitoring and to the controller (502) or 2 separate computer for trend based machine condition monitoring. 11

3. A method for controlling fast actions with automation system 10 module (401) characterized by that the method comprising: - scanning the state of one or more inputs (1601) - providing (1604) the input signal as data to controller (502) or separate computer - running machine condition monitoring application in the controller (502) or separate computer - calculating within the 10 module at least the peak values or the root mean square from the input signal - stopping a motor and/or releasing a brake if a parametrizable limit is reached with the calculation - while receiving control inputs (1605) from controller (502). N N O N O K N I Ac 2 © ~ co O N 12