US20110029254A1 - Field device for determining and monitoring process variable in process automation systems - Google Patents

Field device for determining and monitoring process variable in process automation systems Download PDF

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Publication number
US20110029254A1
US20110029254A1 US12/311,854 US31185407A US2011029254A1 US 20110029254 A1 US20110029254 A1 US 20110029254A1 US 31185407 A US31185407 A US 31185407A US 2011029254 A1 US2011029254 A1 US 2011029254A1
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Prior art keywords
field device
sensor
control
application
evaluation unit
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Abandoned
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US12/311,854
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English (en)
Inventor
Udo Grittke
Axel Humpert
Dietmar Fruhauf
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Endress and Hauser SE and Co KG
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Endress and Hauser SE and Co KG
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Assigned to ENDRESS + HAUSER GMBH + CO. KG reassignment ENDRESS + HAUSER GMBH + CO. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FRUHAUF, DIETMAR, GRITTKE, UDO, HUMPERT, AXEL
Publication of US20110029254A1 publication Critical patent/US20110029254A1/en
Assigned to ENDRESS+HAUSER SE+CO.KG reassignment ENDRESS+HAUSER SE+CO.KG CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: ENDRESS+HAUSER GMBH+CO. KG
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K19/00—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits
    • H03K19/02—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components
    • H03K19/173—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components
    • H03K19/177—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components arranged in matrix form
    • H03K19/17748—Structural details of configuration resources
    • H03K19/17752—Structural details of configuration resources for hot reconfiguration
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D18/00—Testing or calibrating apparatus or arrangements provided for in groups G01D1/00 - G01D15/00
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D3/00—Indicating or recording apparatus with provision for the special purposes referred to in the subgroups
    • G01D3/02—Indicating or recording apparatus with provision for the special purposes referred to in the subgroups with provision for altering or correcting the law of variation
    • G01D3/022—Indicating or recording apparatus with provision for the special purposes referred to in the subgroups with provision for altering or correcting the law of variation having an ideal characteristic, map or correction data stored in a digital memory
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K19/00—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits
    • H03K19/02—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components
    • H03K19/173—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components
    • H03K19/177—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components arranged in matrix form
    • H03K19/17724—Structural details of logic blocks
    • H03K19/17732—Macroblocks
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K19/00—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits
    • H03K19/02—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components
    • H03K19/173—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components
    • H03K19/177—Logic circuits, i.e. having at least two inputs acting on one output; Inverting circuits using specified components using elementary logic circuits as components arranged in matrix form
    • H03K19/17748—Structural details of configuration resources
    • H03K19/17756—Structural details of configuration resources for partial configuration or partial reconfiguration

Definitions

  • the invention relates to a field device for determining or monitoring a process variable in process automation.
  • the field device includes: A sensor, which works according to a defined measuring principle; and a control/evaluation unit, which conditions and evaluates the measurement data delivered by the sensor.
  • field devices are often applied, which serve for determining and monitoring process variables.
  • field devices include fill level measuring devices, flow measuring devices, analytical measuring devices, pressure and temperature measuring devices, moisture and conductivity measuring devices, and density and viscosity measuring devices.
  • the sensors of these field devices register the corresponding process variables, e.g. fill level, flow, pH value, substance concentration, pressure, temperature, moisture, conductivity, density or viscosity.
  • field devices are, however, also actuators, e.g. valves or pumps, via which, for example, the flow of a liquid in a pipeline or the fill level in a container is changeable.
  • actuators e.g. valves or pumps
  • a large number of such field devices are available from members of the firm, Endress +Hauser.
  • field devices in modern automation technology plants are connected via communication networks (HART multidrop, point to point connection, Profibus, Foundation Fieldbus, etc.) with a superordinated unit, which is referred to as a control system or control room.
  • This superordinated unit serves for process control, process visualizing, process monitoring, as well as for start-up, or for servicing, of the field devices.
  • Necessary supplemental components for operation of fieldbus systems i.e. components, which are directly connected to a fieldbus and which serve especially for communication with the superordinated units, are likewise frequently referred to as field devices.
  • These supplemental components include e.g. remote I/Os, gateways, linking devices or controllers.
  • control system applications such as e.g. Simatic S7 of Siemens, Freelance of ABB and Delta V of Emerson.
  • An essential aspect of open communication systems is the interoperability and exchangeability of devices of different manufacturers.
  • sensors or actuators of various manufacturers can be applied without problem together in a plant.
  • an option is to replace a field device of one manufacturer with a functionally equal field device of another manufacturer, whereby the customer has a highest measure of freedom in the configuration of its process installation.
  • Field devices are becoming increasingly complex as regards their functionality. Besides pure, measured value processing, diagnostic tasks and, above all, communication tasks, which the field devices must fulfill with respect to the installed bus systems, are becoming always more complex. Still more complex are functionalities in field devices having multisensor capability. These field devices must be able to determine or to monitor, simultaneously, at least two process variables. In order to meet these increasing requirements, a number of microcontrollers are often provided in parallel in a field device.
  • microcontrollers An advantage in the use of microcontrollers is that, via application-specific software programs, which run in these microcontrollers, the most varied of functionalities are implementable. In addition, program changes can be made relatively simply. Program controlled field devices are flexible to a high degree. This high flexibility is, however, gained with the disadvantage, that, because of the sequential progression through the program, the processing speed is slowed.
  • ASICs Application Specific Integrated Circuits
  • ASICs Application Specific Integrated Circuits
  • ASICs Disadvantageous in the case of the application of ASICs is that the functionality of these chips is fixedly predetermined. A subsequent changing of the functionality of these chips is not directly possible. Furthermore, the use of ASICs makes sense only in the case of relatively large piece numbers, since the developmental effort and the therewith connected costs are high.
  • WO 03/098154 proposes a configurable field device, wherein a reconfigurable logic chip in the form of a FPGA is provided.
  • the logic chip has at least one microcontroller, which is also referred to as an embedded controller.
  • the logic chip is configured during system start. After the configuration is finished, the required software is loaded into the microcontroller.
  • the reconfigurable logic chip required in such case must have available sufficient resources, such as sufficient logic, wiring and memory resources, in order to fulfill the desired functionalities.
  • Logic chips with many resources require much energy, and, with that energy, their use in process automation limitless. Disadvantageous in the use of logic chips with few resources, and, thus, having smaller energy consumption, is the considerable limitation in the functionality of the corresponding field device.
  • An object of the invention is to provide a field device, which is suitable for flexible use in the most varied of applications in process automation technology.
  • control/evaluation unit is embodied, at least partially, as a reconfigurable logic chip FPGA having a plurality of dynamically reconfigurable function modules—involved is, thus, a partially dynamically reconfigurable logic chip.
  • an interface is provided, via which the control/evaluation unit receives sensor- and application-specific information concerning the defined sensor type in the defined process application.
  • the control/evaluation unit configures the function modules corresponding to the sensor- and application-specific information in such a manner, that the field device is adapted optimally to the process variable to be ascertained, or to be monitored, and to the current process application.
  • the selected sensor- and application-specific information is, for example, loaded during manufacture into the flash memory and subsequently configured by the control/evaluation unit.
  • the complete functionality for the most varied of applications and sensors can be loaded into the flash memory, so that, subsequently, as regards selection of the sensor for the particular application, a large flexibility is present.
  • An option is, then, to reconfigure the field device for another application at a later point in time, to the extent desired.
  • the function modules involve microprocessors with different bus widths, A/D converters or D/A converters with different bit resolutions, signal filters with different filter functions, different scalings of evaluating algorithms (or polynomials, as the case may be), different modems, different electrical current control units or operating units for different in/output units.
  • control/evaluation unit has at least one static region, in which is permanently configured at least one fundamental component, such as, for example, the microcontroller. Since the components in the static region are preferably permanently connected, they are distinguished by a high processing speed. A partially dynamic reconfiguration makes, here, little sense, since—in the case of application of only one microcontroller—this must be configured permanently in its function as control unit for the configuring of the function modules.
  • the sensor-specific information involves information, which characterizes the sensor in its function for determining or monitoring a process variable via a defined measuring principle. If, for example, the process variable to be monitored is flow, then flow measuring devices can be applied, which operate, for example, based on the Coriolis principle or on the principle of Karman's vortex street. Furthermore, flow can be ascertained via measuring the travel-time difference of ultrasonic measurement signals, or by the principle of electromagnetic induction.
  • process variable can be the most varied of physical or chemical, process variables.
  • process variables Fill level, pressure, flow, temperature, conductivity, pH-value, turbidity, density, viscosity or concentration of a chemical substance.
  • the application-specific information can include information concerning the defined application, in which the field device is applied in the process.
  • this information can be information concerning in which operational manner e.g. a pressure sensor works.
  • Possible types of operation of a pressure sensor include pressure measurement, fill level measurement and flow measurement. In the case of pressure measurement, it is, in turn, distinguished, whether the field device measures relative pressure, absolute pressure or pressure difference, compensated with relative pressure.
  • the application-specific information can be information on whether the field device is applied in a process, wherein the process variable to be measured essentially changes continuously, or whether, in the monitored process, abrupt changes of the process variable are to be expected.
  • An example of an-abruptly changing process variable is a pressure shock, or so-called water hammer.
  • a pressure shock arises, when, in a liquid conveying pipeline, a retractable assembly, or a valve, is closed, or opened, too rapidly.
  • the kinetic energy of the liquid column moving in the pipeline brings about, in front of the retractable assembly, through its low compression module, a very rapid rise in pressure.
  • there arises there first a vapor bubble having a lower pressure while the liquid column moves further.
  • the liquid column reverses its direction of movement and pounds back into the retractable assembly.
  • the retractable assembly and/or the connecting pipelines can be destroyed. Similar problems can occur during the opening of the retractable assembly. It is quite usual, that pressure changes before and behind the retractable assembly can lie in a range of 20 bar to 100 mbar absolute. These abrupt pressure increases and pressure decreases occur so rapidly, that they are not at all measurable with conventional pressure measuring devices. Conventional pressure measuring devices are distinguished, preferably, by a high accuracy of measurement in the case of slowly changing pressures. Since the extreme pressure fluctuations lead, not seldomly, to the failure of the pressure measuring device, it is indispensible in the context of predictive maintenance to register pressure surges, to log them, and, on occasion, suitably to react to them.
  • the field device of the invention whose control/evaluation unit is configured to serve as that of a pressure measuring device, the occurrence of water hammers can be detected. If is the occurrence of water hammer and its effects are detectable, then suitable countermeasures can be taken, to counteract abrupt rising and falling of pressure values in the pipeline.
  • the pipeline can have rapidly controllable valves, which, in the presence of knowledge of the pressure shock, perform suitable compensation procedures.
  • a further development of the field device of the invention provides that, in ongoing measurement operation, a monitoring function checks, whether abrupt changes of the process variable are occurring. If abrupt changes are evident, or their occurrence is known in advance, then the control/evaluation unit configures function modules, especially the A/D, and D/A, converters and filter to have higher bit-resolution than is the case, when the process variable slowly changes or when it essentially assumes a constant value.
  • the main emphasis is on providing a pressure measurement having a high accuracy of measurement.
  • the electronic evaluation components are so selected, that they have a high bit resolution. The processing speed is, thus, relatively slow.
  • control/evaluation unit configures, at least temporarily (for instance, after the opening or closing of a valve), parallel branches of function modules.
  • the first branch is suited for processing abruptly changing process variables; the second branch is designed for processing essentially continuously changing process variables. Either the two branches work in parallel, or the branch suitable for the application is activated via the monitoring function.
  • FIG. 1 an embodiment of the partially dynamically configured, control/evaluation unit of the invention for a pressure measuring device
  • FIG. 2 a three-dimensional arrangement of a plurality of functionalities, with which different control/evaluating units for field devices can be configured.
  • FIG. 1 shows the control/evaluation unit 2 of a sensor 1 , in this case, a pressure sensor, which is embodied in the form of a partially dynamically reconfigurable, logic chip FPGA 2 having a plurality of dynamically reconfigurable function modules 4 .
  • a sensor 1 in this case, a pressure sensor
  • FPGA 2 partially dynamically reconfigurable, logic chip FPGA 2 having a plurality of dynamically reconfigurable function modules 4 .
  • Two alternative methods for partially dynamically reconfiguring logic chips are described in two International patent applications, which have the same filing date as the present International patent application and which likewise claim the priorities of three patent applications filed on 17 Oct. 2006, namely: DE 10 2006 049 509.8, DE 10 2006 049 501.2, DE 10 2006 049 502.0. The content of these two International patent applications is expressly incorporated here by reference.
  • control/evaluation unit 2 Provided on the control/evaluation unit 2 is at least one interface 25 , via which the control/evaluation unit 2 receives sensor- and application-specific information concerning a defined sensor type—here, thus, the pressure sensor 1 —in a defined process application—here, pressure measurement.
  • Control/evaluation unit 2 configures the function modules 4 corresponding to the sensor- and application-specific information made available via the interface 25 , so that the field device 3 is optimally adapted to the process variable p to be ascertained or monitored and to the current process application of the field device 3 .
  • the control/evaluation unit 2 receives the sensor- and application-specific information preferably during the manufacture of the field device 3 .
  • An option is, however, also, to reconfigure the field device 3 for another application at a later point in time. This reconfiguration can likewise be brought about via the operating, or servicing, tool 12 .
  • the function modules 4 are stored in the FLASH memory 18 .
  • the resistance or capacitance values R, C are fed to A/D converter 6 and then filtered via the filter 7 a.
  • the pressure p reigning in the process is ascertained.
  • control/evaluation unit I can be dynamically so configured, that the field device 3 is suitable, as a function of relevant application, alternatively for flow measurement or for fill level measurement.
  • Corresponding function modules L, ⁇ can be dynamically partially configured.
  • the currently required function modules 4 are, on demand of the control program running in the microcontroller 23 , partially dynamically configured in the logic chip FPGA.
  • the configuring of the function modules 4 occurs in simple manner via a configuration bit stream, which is loaded from a memory FLASH 27 .
  • the configuring of the function modules 4 is described in detail in the two already earlier cited International patent applications, whose content is incorporated by reference in the present patent application.
  • Dynamic region DR is provided for the individual, dynamically configurable, function modules 4 .
  • the function modules are always only partially configured, and, thus, resources used, which are currently required (see the first International patent application).
  • the control/evaluation unit 2 consumes only a fraction of the energy, which a usual FPGA requires. If this advantage is combined with the advantage of the solution based on permanently connected ASIC structures (see second International patent application), then the control/evaluation unit of the invention is distinguished additionally by the high processing speed of an ASIC.
  • the function modules 4 provide all needed functionalities, such as, for example, digital/analog conversion and the filtering of the measurement signal, the generating of an output value for the communication circuit, and the operating of the display/service unit.
  • a field device 3 having a partially dynamically reconfigurable logic chip FPGA 2 offers the advantage that only currently required function modules 4 are configured. All additional functionalities are, in principle, readily available, since they are stored as function modules 4 in a memory element 18 and can be configured at any time, to the extent that corresponding resources are available.
  • the field device 3 can be supplied with energy (loop powered) via a fieldbus 24 , or a process control loop 10 , without a separate energy supply line being necessary.
  • any field device 3 for determining a process variable can be configured. Usually, such configuration occurs within the framework of the manufacturing process.
  • the information is stored in the FLASH memory 18 .
  • the control/evaluation unit 2 can also, at any time, be adapted optimally to the particular application.
  • the field device 3 can be equipped highly flexibly with the functionality of different device classifications. These are indicated in FIG. 2 with the labels of the planes, BASIC, STANDARD and ENHANCED.
  • FIG. 2 The three-dimensional display shown in FIG. 2 will now be described in detail: In the rows of the front plane are presented a sensible sorting of different components of a field device 3 . Of course, the illustrated functionalities represent only a selection. Given the multiplicity of possible variations, only a few are explicitly presented. The corresponding configurable function modules are stored in the field device 3 .
  • I/O input/output—are some of the known inputs and outputs:
  • test patterns such as suitable in manufacture or for purposes of predictive maintenance or for SIL applications.
  • adaptive function blocks such as filter and algorithms.
  • the functionalities of a field device 3 of the lowest product-classification are selected—in FIG. 2 , the selected function modules 4 are provided each with a circle.
  • the partially configured field device 3 is a radiometric field device, which ascertains fill level of a fill substance in a container, and which outputs, as measured value, a 4-20 mA signal. Furthermore, an in/output unit is provided and the field device is able to communicate via the HART protocol.

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  • Physics & Mathematics (AREA)
  • Mathematical Physics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Computing Systems (AREA)
  • General Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Technology Law (AREA)
  • Logic Circuits (AREA)
  • Programmable Controllers (AREA)
  • Arrangements For Transmission Of Measured Signals (AREA)
  • Tests Of Electronic Circuits (AREA)
  • Testing Or Calibration Of Command Recording Devices (AREA)
US12/311,854 2006-10-17 2007-09-10 Field device for determining and monitoring process variable in process automation systems Abandoned US20110029254A1 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
DE102006049501 2006-10-17
DE102006049502 2006-10-17
DE102006049502.0 2006-10-17
DE102006049509.8 2006-10-17
DE102006049501.2 2006-10-17
DE102006049509 2006-10-17
PCT/EP2007/059441 WO2008046695A1 (de) 2006-10-17 2007-09-10 FELDGERÄT ZUR BESTIMMUNG UND ÜBERWACHUNG EINER PROZESSGRÖßE IN DER PROZESSAUTOMATISIERUNG

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US12/311,855 Expired - Fee Related US8271773B2 (en) 2006-10-17 2007-09-10 Configurable field device for use in process automation systems
US12/311,854 Abandoned US20110029254A1 (en) 2006-10-17 2007-09-10 Field device for determining and monitoring process variable in process automation systems
US12/311,856 Abandoned US20110025376A1 (en) 2006-10-17 2007-09-10 System for the flexible configuration of functional modules

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US12/311,856 Abandoned US20110025376A1 (en) 2006-10-17 2007-09-10 System for the flexible configuration of functional modules

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US20110025376A1 (en) 2011-02-03
US8271773B2 (en) 2012-09-18
EP2082191A1 (de) 2009-07-29
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