WO2016150500A1

WO2016150500A1 - Method for operating an automation system, automation system and automation device

Info

Publication number: WO2016150500A1
Application number: PCT/EP2015/056420
Authority: WO
Inventors: Thomas Hubauer; Steffen Lamparter; Martin RINGSQUANDL
Original assignee: Siemens Aktiengesellschaft
Priority date: 2015-03-25
Filing date: 2015-03-25
Publication date: 2016-09-29

Abstract

A method for operating an automation system (30) including automation devices (12₁- 12_n), the method comprising the steps of communicating a query (13) to some automation device (12₁- 12_n) in a global language (G₁) over an access interface (11), generating local operational data (D_L11- D_L1n) associated with the automation device (12₁-12_n), wherein the local operational data (D_L11- D_Lln) are generated in a local language (L₁₁- L₁₄), converting the local operational data (D_L11- D_Lln) into global operational data (D_G11- D_G1n) by translating the local operational data (D_L11-^DLln) from the local language (L_ll- L_1n) into the global language (G₁), and returning, in response to the query (13), the global operational data (D_G11- D_Gln) associated with the automation device (12₁- 12_n) through the access interface (11). The implemented global language facilitates data access and processing on any levels of the automation hierarchy system.

Description

Method for operating an automation system, automation system and automation device

This disclosure relates to a method for operating an

automation system including a plurality of automation devices, an automation system and an automation device. Effective and efficient methods for handling huge amounts of data become increasingly important. Especially data

management in heterogeneous information technology (IT) landscapes of manufacturing industries which combine central IT infrastructures including cloud computing resources with increasingly powerful decentralized automation systems is becoming more complex and challenging.

In an attempt to maintain and improve competitiveness, manufacturing companies acquire and analyze data for

calculation and reporting of performance indices, quality management, optimization of maintenance activities, tracking and tracing of materials and products, documentation of processes and many more. Today, a strictly hierarchical data management architecture along an automation pyramid is used for above mentioned purposes. Here, data can be stored and processed on all levels including servers in the cloud, manufacturing

execution systems (MES) , supervisory and data acquisition (SCADA) systems and even on programmable logic controllers (PLC) and field devices.

The long-term storage, archiving and analysis are performed on MES or higher levels using historians and enterprise data warehouses. Integration of data from heterogeneous data sources is carried out statically using Extract, Transform and Load (ETL) processes. Analytical algorithms, such as performance indicator or monitoring rules, are directly specified according to the underlying data schemas and manually deployed to the corresponding systems/devices (e.g. warehouses, SCADA systems, PLCs, etc.). It is one object of the present disclosure to improve

operation method of an automation system including a

plurality of automation devices.

Accordingly, a method for operating an automation system is suggested. The automation system includes a plurality of automation devices. The method comprises the steps of

providing an access interface for communicating a query to at least one automation device of the plurality of automation devices, wherein the query is communicated in a global language, generating local operational data associated with the at least one automation device, wherein the local

operational data are generated in a local language,

converting the local operation data into global operational data by translating the local operational data from the local language into the global language and returning, in response to the query, the global operational data converted from the local operational data associated with the at least one automation device through the access interface. The automation system can relate to a control system for operating equipment such as machinery processes in factories with minimal or reduced human intervention, i.e. at least some processes are completely automated. In particular, the automation system can be configured to control manufacturing processes, e.g. by controlling field level production units. Examples for an automation system are chemical plants, petrochemical (oil) and refineries, boiler controls and power plant systems, nuclear power plants, environmental control systems, water management systems, metallurgical process plants, pharmaceutical manufacturing, sugar-refining plants and/or dry-cargo and bulk oil carrier ships.

In particular, operate, operating and operation as well as control and controlling can relate to causing a device and/or a process to function, to work, to be in action and/or to have an effect. Alternatively or additionally, the terms operate, operating and operation as well as control and controlling can relate to monitoring, supervising,

overseeing, surveillance, observing, examining a device and/or a process.

In this disclosure, operate, operating and operation and control and controlling refer to the same meaning and may be used interchangeably.

In this disclosure, the term user is not limited to human operator interacting with said automation system but also include automation devices that are capable of generating a query and input the query into the automation system.

The automation system can comprise one or more automation devices. The automation devices can comprise any elements, units and/or devices that can be controlled by another automation device, i.e. human interaction is either not required or at least reduced. For example, the plurality of automation devices can comprise multiple field level units that are controlled by control units. The control units may constitute a control level that is controlled by a supervisory level for data acquisition from underlying levels. The supervisory level may receive and execute tasks and/or queries from organizing systems that analyze the acquired data and/or plan, coordinate and schedule the operation of the automation system. The

organizing systems may then form a business and operational management level of the automation system.

The query can relate to a task to be executed by the

automation system. Further, the query can relate to an instruction to access and/or process data, for example, specific operational data such as temperature, workload, manufacturing quality, etc., and thereby initiating a scanning and/or sampling process of the operational data by the automation devices. Additionally or alternatively, the query may require an interrogation of a database, a data warehouse and/or a data server. For example, the query can comprise data access and analysis including, but not limited to statistical, event-based, and logic-based approaches, such as, variance, cross-correlations, correlations of specific operational data, database interrogation, calculation of business and/or management indexes including key performance indicator, failure production and/or overall equipment effectiveness .

In particular, communicating a query from the access

interface to the automation devices can comprise transmitting electronic, mechanical, physical, optical and/or thermal signals. The query may be either directly communicated to the corresponding automation device or forwarded to the

corresponding control device that controls the automation device which is to execute the task.

The global language can comprise a set of strings of symbols that may be constrained by specific rules. The global language can relate to a communication means that enables the automation devices to communicate with one another and/or with the access interface. Further, the global language can enable and/or facilitate a communication between the user and the automation devices. In particular, the global language can be an artificial language and can comprise a constructed language and/or a formal language. For example, the global language comprises a machine language, a programming

language, a communication protocol and/or an assembly language .

In particular, the local operational data can comprise at least a subset of parameters for characterizing an identity, an attribute and/or a status of the respective automation device. In particular, the local operational data can include data required for responding the query, e.g. for executing the task. The local operational data may be acquired upon receiving the query and/or stored locally at the respective automation device and available for access. In particular, the query can contain one or more analytical tasks. For example, the query includes an analysis of

specific local and/or global operational data, thereby requiring accessing and processing said operational data. The local language can comprise a set of strings of symbols that may be constrained by specific rules. For example, the local language can be defined by specific syntax and

semantics and use numbers and/or alphabetic characters. As an example, the local languages of one of the automation devices can be given by the binary code that represents texts and/or processing instructions using two different digits 0 and 1.

Each automation device can have its own local language. In particular, the automation devices can be configured to provide their own local operational data using the respective local language. In particular, the local language can be an artificial language and can comprise a constructed language and/or a formal language. For example, the local language comprises a machine language, a programming language, a communication protocol and/or an assembly language.

In particular, the local operational data are provided in the local language of the automation device which the local operational data are associated with. The local operational data are converted into the global operational data by a translating process from the local language into the global language. Accordingly, the global operational data may be associated with the automation device that provides the local operational data before the translation process.

The global language can provide the automation system with a common, uniform language that the plurality of automation devices can use for describing the local operational data. Further, the global language can enable the automation devices to communicate and/or interact with one another and/or the user. According to an embodiment, the global language is an

ontology-based language.

Generally, an ontology can relate to a formal naming and definition of the terms, types, properties and

interrelationships of parameters, devices, units, data and/or any other elements of a system, thereby enabling an accurate interpretation of data from multiple heterogeneous data sources. An ontology-based language can involve the use of the ontologies to effectively combine data from multiple heterogeneous data sources. In particular, the ontologies can represent concepts and their relationships to one another and, for example, be used to overcome a semantic

heterogeneity in data sources. Furthermore, the ontologies can enable the unambiguous identification of entities in heterogeneous information systems and an assertion of applicable relationships connecting the entities together.

Different architectures for implementing an ontology-based global language in the system may be applied. In the simplest approach, a single ontology can be used as a global reference model in the system. Alternatively, multiple ontologies, each modelling an individual data source, can be used in

combination for integration. In addition or alternatively, multiple ontologies can be used to subscribe vocabulary to a combined, top-level ontology, which defines the basic terms of the domain.

According to a further embodiment, the method further

comprises the step of generating, by the at least one

automation device, the local operational data associated with said automation device in the global language as the global operational data. The automation devices might be equipped with a measurement device, a sensor device and/or a monitoring device that is configured to measure, sense and/or monitor relevant local operational data of the automation device.

For example, the automation devices can comprise a data processing unit for converting the local operational data into the global operational data by translating the local operational data from the local language into the global language. In particular, the automation devices can transmit the acquired operational data to the access interface.

Furthermore, such a processing unit can be used for data analysis, e.g. for calculating business-relevant indexes, statistical relevant values, etc.

A processing power, i.e. a performance characterized by an amount of useful work accomplished by the automation system compared to the time and resources used, can be optimized by exploiting the local processing power associated with the automation devices, thereby distributing the processing work over the plurality of automation devices.

According to a further embodiment, the method further comprises the step of storing, by the at least one automation device, the global operational data in a local storage unit.

In particular, the local storage unit is configured to store the global operational data and/or the local operational data. Furthermore, results from a data analysis and/or data processing by the aforementioned processing unit of the automation device may be stored in the storage unit. For example, the local storage unit can be provided as a

database, a data carrier, a memory medium and/or a data medium.

A usage of a total available storage capacity can be

optimized by locally storing local and/or global operational data in the local storage units of the automation devices, thereby saving time requirements for data accessing and costs for a global storage medium.

According to a further embodiment, the method further

comprises the step of submitting, by the at least one

automation device, the global operational data to the access interface .

In particular, the automation devices are capable of self- submitting the global operational data to the access

interface .

The self-submission of the global operational data by the automation devices can reduce the time requirement for the data access through the access interface.

According to a further embodiment, the method further

comprises the steps of providing at least one domain model for characterizing the at least one automation device, wherein the at least one domain model is provided in the global language, and converting the local operational data into global operational data according to the at least one domain model. For example, the automation system may include one or more system domains specified by functionality, structure,

physical location, position in a hierarchy of control layers, etc. A domain model can describe the one or more system domains in a semantic modelling language, e.g. ontology formalized using the Web Ontology Language (OWL) or Resource Description Framework (RDF) , that is independent of the underlying devices, ( sub- ) systems and/or data infrastructure. The domain model can represent abstract concepts, e.g. "a sensor device", and relations, e.g. "connected to a

programmable logic controller (PLC)" or "takes measurements in a field-level production unit". In particular, the domain model can hide local operational data that are irrelevant with respect to the query, e.g. location, data schema and the physical implementation details about the automation device, from the user.

In particular, a domain model can be a conceptual and/or descriptive model describing various entities, their

attribute, roles and relationships and/or the constraints that govern the respective domain. The domain model can represent the vocabulary and key concepts of the respective domain. Further, the domain model can identify the

relationships among all the entities within the scope of the respective domain. In particular, the domain model can identify the attributes of the entities and their

relationships among one another. In the automation system, the domain model can describe a subset of the automation devices in terms of their function and/or their structure and the relationships of the

automation devices to one another. As an example, the

automation devices can be assigned to one of the control layers in a hierarchical control layer system, comprising a field level, a direct control level, a data acquisition level, an information system level, a data analysis level and/or an enterprise resource planning level. At least one of the control levels can be associated with a domain level that specifies elements, units and devices and the

interrelationships thereof in said control level so as to define them unambiguously.

According to a further embodiment, the method further

comprises the steps of providing at least one analytics model for characterizing the query and translating the query into the global language according to said analytics model.

The analytics model can be provided as mathematical

analytical function that is configured to solve a given question and/or problem. In the automation system, the analytics model can be deployed to the automation system in order to calculate business-relevant indexes and/or to obtain statistical data.

In particular, analytics models can comprise serialized and deployable mathematical models and, for example, include linear and non-linear regression models, decision trees, random forest models, support vector machines, etc. In particular, the analytics model can prescribe how to convert the received, in particular arbitrary, query into a form that is compatible with the global language. In particular, the analytics model can be defined using the vocabulary of the domain model and used for classifying the queries according to the domain models. For example, the analytics model is represented using an Extensible-Markup-Language (XML) based file format such as predictive model markup language (PMML) in order to simplify model exchange and reuse.

According to a further embodiment, the method further

comprises the step of simultaneously communicating a

plurality of queries to a plurality of automation devices.

A plurality of queries can comprise multiple queries that are independent from one another. Alternatively or additionally, a (single) query can be divided into a plurality of sub- queries.

The plurality of queries may be executed immediately and/or scheduled to be executed by the local processing units in a distributed manner, thereby exploiting the local processing power of the automation devices and optimizing time and resources required.

In this disclosure, a query is a general term and can

comprise one single query, a plurality of queries and/or a plurality of sub-queries if not expressly stated otherwise. According to a further embodiment, the method further

comprises the steps of planning an execution of the query and executing the query. In particular, the access interface may be provided with a processing unit for analyzing the received query, planning the execution of the query and initiating the execution of the query. In particular, processing, analyzing, executing and/or deploying the query may be performed irrespective of the global language. For example, the query may be processed, analyzed, executed and/or deployed in a local language.

According to a further embodiment, the method further

comprises the step of converting, in an abstraction layer, the local operational data into global operational data by translating, in the abstraction layer, the local operational data from the local language into the global language.

In particular, the abstraction layer is functionally defined structure. Accordingly, central and/or local processing units that perform the translation, a mapping and/or conversion of the local operational data into the global operational data according to the global language can be subsumed into the abstraction layer. In particular, the abstraction layer can be regarded being implemented on top of each of the

automation device, thereby being located between the user and the automation devices.

According to a second aspect, an automation system is

suggested. The automation system comprises a plurality of automation devices and an access interface. At least one automation device of the plurality of automation devices is configured to generate and submit global operational data to the access interface. The access interface is configured to communicate with said automation device.

According to a further embodiment, the automation system is configured to perform the aforementioned method. The automation system facilitates access and processing of data from the plurality of automation devices that form heterogeneous data sources. In the automation system, the storage and processing of the global operational data can be carried out locally at the respective automation device.

Accordingly, the processing power and storage capacity of the automation devices can be exploited and a usage of the available processing power of the automation system is optimized.

In particular, no central database for storing data from all automation devices is required, thereby reducing time and resources required for the storage of the data. For example, no powerful librarian, historian, database, data warehouse etc. are required for accessing and processing data from the automation system. Furthermore, a global language can be implemented into the automation system such that a

communication between a user and the automation devices as well as of the automation devices with one another is simplified .

For example, an exchange of one of the automation devices, e.g. a sensor device, does not require a restructuring and/or reorganization of the data structure, but the global language can be pushed onto the new sensor device such that the time and resources required for its integration into the

automation system can be reduced. The global operational data can include measurement results, sensor data, monitored parameters, program code, proprietary and/or time-based parameters, vocabulary, tags and/or

database inquiries. In particular, the local operational data and/or the global operational data are computer-readable data. In particular, the automation devices are configured to self-submit their available processing power and/or available storage capacity that can be potentially used for the

execution of the query. According to a further embodiment, the access interface includes a user interface device, a planning unit and an execution unit. The user interface device is configured for receiving the query. The planning unit is configured for planning a process required for carrying out the query. The execution unit is configured for communicating the query to the plurality of automation devices and for executing said process .

The access interface can be configured for analyzing the received query and to plan and/or schedule the execution of the query. In particular, the received query is analyzed according to at least one analytics model the access

interface is provided with. For example, said analytics model can be compatible with domain models that define at least a subset of the automation devices. Furthermore, the access interface is configured to plan an execution of the received query and to communicate the execution of the query to the automation devices, thereby initiating the execution of the query .

According to a further embodiment, the plurality of

automation devices are hierarchically arranged in a plurality of automation system levels including a field level, a direct control level, a data acquisition level, an information system level, a data analysis level and/or an enterprise resource planning level. The automation system can comprise further automation system levels including a local control level, a supervisory level, a production control level, a manufacturing operation level, a batch control level, a continuous control level, a discrete control level, etc.

The field level can comprise production units, manufacturing devices, local working units, transportation elements, switches, circuits and/or any other devices, units and/or elements that can perform physical and/or mechanical

services .

A direct control level can comprise an intelligent control device, programmable logic controller, industrial

communication busses, control center, input/output

termination unit, a proportional-integral-derivative

controller, a memory chip controller and/or any other control unit that can control automation devices on the field level. For example, the direct control level may comprise a radio- frequency identification (RFID) device.

The data acquisition level can comprise a supervisory and data acquisition node, isolating switch, local and/or bridge SCADA, human-machine-interface node, technical support node and/or any other automation devices that are configured to acquire local and/or global operational data from the

underlying automation system levels. The information system level can comprise an application server, a historian database server, a central control station, a web server, an alarm server, mobile technical support devices and/or any other automation devices that are configured to allow access to and/or store relevant

information from the acquired data from the data acquisition level .

The data analysis level can comprise a quality and downtime analysis client, a corporate client and/or any other

automation devices that are involved in analyzing data that are acquired and/or output from the underlying automation system levels.

The enterprise resource planning level can comprise a central scheduling, planning, logistics, operational management client and/or computer that is on top of the hierarchy of the automation system levels. According to a third aspect, an automation device is

suggested. The automation device comprises a data acquisition unit, a storage unit and a translation unit. The data

acquisition unit is configured to generate local operational data associated with the automation device, wherein the local operational data are generated in a local language. The translation unit is configured to convert the local

operational data into global operational data by translating the local operational data from the local language into a global language. The storage unit is configured to store the local and/or global operational data.

The respective entity, e.g. the processing units and/or devices, may be implemented in hardware and/or in software. If said entity is implemented in hardware, it may be embodied as a device, e.g. as a computer or as a processor or as a part of a system, e.g. a computer system. If said entity is implemented in software it may be embodied as a computer program product, as a function, as a routine, as a program code or as an executable object.

Any embodiment of the first aspect may be combined with any embodiment of the first aspect to obtain another embodiment of the first aspect.

According to a further aspect, the invention relates to a computer program product comprising a program code for executing the above-described method for operating an

automation system when run on at least one computer.

A computer program product, such as a computer program means, may be embodied as a memory card, USB stick, CD-ROM, DVD or as a file which may be downloaded from a server in a network. For example, such a file may be provided by transferring the file comprising the computer program product from a wireless communication network. The embodiments and features described with reference to the automation device and/or automation system of this disclosure apply mutatis mutandis to the method of the present

invention .

Further possible implementations or alternative solutions of the invention also encompass combinations - that are not explicitly mentioned herein - of features described above or below with regard to the embodiments. The person skilled in the art may also add individual or isolated aspects and features to the most basic form of the invention.

Further embodiments, features and advantages of the present invention will become apparent from the subsequent

description and dependent claims, taken in conjunction with the accompanying drawings, in which:

Fig. 1 shows an illustrative view of an embodiment for

operation of an automatic system;

Fig. 2 shows an illustrative view of a further embodiment for operation of a further automatic system;

Fig. 3 shows an embodiment of a further automatic system;

Fig. 4 shows a further embodiment of a further automatic system; and

Fig. 5 illustrates a further embodiment of operation of a further automatic system.

In the Figures, like reference numerals designate like or functionally equivalent elements, unless otherwise indicated. Fig. 1 shows an illustrative view of a first embodiment for operation of an automatic system 10. The automation system 10 including a plurality of automation devices 12i - 12_n is provided with an access interface 11 for the communication between a user U and the automation devices 12i - 12_n. The automation devices 12i - 12_n generate the local operational data D_L11 - D_Lln, respectively. In addition, the automation device 12i - 12_n is provided with a proprietary local language L_u - L_ln, respectively. For example, at least one of the local languages Lu - L_ln comprises a binary code, a programming language, a machine language, a communication protocol, etc.

The access interface 11 includes a translation unit 14. The translation unit 14 is configured to convert the local operational data D_L11 - D_Lln into global operational data D_G11 - D_Gln, respectively, by translating the local operational data D_Lii - D_Lln from the respective local languages Lu - L_ln into the global language Gi . Furthermore, the access interface 11 is configured to translate a query 13 received from the user U into the global language Gi . Accordingly, both the query 13 and the global operational data D_G11 - D_Gln are provided in a common language, namely the global language Gi, and an implementation, transmission and/or execution of the query 13 by the automation devices 12i - 12_n is thereby facilitated. The automation devices 12i - 12_n comprise, for example, field level manufacturing and/or production unit, control unit for controlling the field level units, supervisory units, data acquisition units, database and/or data warehouse, data storage unit, data analysis unit, data processing unit, coordinating computer system, clients, gateways and/or business, management, operational and/or organizational unit.

Fig. 2 shows an illustrative view of a second embodiment for operation of a further automation system 20.

The automation system 20 comprises a plurality of automation devices 22i - 22_m and is provided with an access interface 21 that enables communication between the user U and the plurality of automation devices 22i - 22_m. The user U inputs a query 13, e.g. via an input/output terminal and/or user interface, to the access interface 21. Generally, the query 13 from the user U before being input into the automation system 20 can be formulated in any language.

The access interface 21 comprises a local abstraction layer 24 and a global abstraction layer 29. The global abstraction layer 29 and the local abstraction layer 24 together form an abstraction layer. The global abstraction layer comprises a translation unit 26, a planning unit 27 and an execution unit 28.

The translation unit 26 is configured to translate the received query 13 into the global language G₂. plurality of analytics models 26i - 26_j are implemented in the translation unit 26. Each of the analytics models 26i - 26_j describes, specifies, defines and/or prescribes a subset of

possible/potential queries that can executed out by the automation system 20. The translation unit 26 translates the received query 13 into the global language G₂ according to one or more analytics models 26i - 26_j the query 13 is related to. In particular, the analytics models 26i - 26_j provide rules, e.g. syntax and semantics, for mapping the received queries 13 using the global language G₂.

The planning unit 27 is configured to plan an execution process P for carrying out the received query 13 that are translated into the global language G₂ by the translation unit 26. In particular, the planning unit 27 analyzes the received and translated queries 13 and, if applicable, divides the queries 13 into single queries and/or into a plurality of sub-queries, wherein each single query and/or sub-query can be executed by at least one of the automation devices 22i - 22_m. In particular, the planning unit 27 is configured to take an available storage capacity and/or processing power with at least one of the automation devices 22i - 22_m into account for the execution process P. For example, the planning unit 27 generates the execution process P by distributing the storage and/or execution of the

received query 13 over a subset of automation devices 22i - 22_m. In particular, the planning unit 27 is configured to designate the automation devices to execute the single queries and/or sub-queries.

The execution unit 28 receives the execution process P from the planning unit 27. The execution unit 28 is configured to communicate with the automation devices 22i - 22_m and, if required by the execution process P, transmit/forward the single queries and/or the sub-queries to the respective designated automation devices 22i - 22_m. For this purpose, the execution unit 28 is configured to split up and/or divide the received query 13 into the single queries and/or the plurality of sub-queries according to the execution process P.

The automation devices 22i - 22_m generate their own local operational data D_L21 - D_L2m, respectively, wherein each automation device 22i - 22_m generates the local operational data D_L2i - D_L2m in its local language L₂₁ - L_2m, respectively. The automation devices 22i, 22₃, 22₆ have a same or similar structure and/or function, as indicated by a circular shape in Fig. 2, and form a first subset. The automation devices

22₂, 22₄ have a same or similar structure and/or function, as indicated by a rectangular shape in Fig. 2, and form a second subset. Further, the automation devices 22₅, 22_m have a same or similar structure and/or function, as indicated by a diamond shape in Fig. 2, and form a third subset. The local abstraction layer 24 is provided with a plurality of domain models 25i - 25±, wherein each domain model describes at least one subset of automation devices 22i - 22_m. In

addition, at least one of the subsets of automation devices 22i - 22_m may be described by more than one domain model 25i - 25±. The local abstraction layer 24 comprises a local translation unit that is configured to convert the local operational data D_L2i - D_L2m into global operational data D_G21 - D_G2m,

respectively. In particular, the local abstraction layer 24 translates the local operational data D_L2i - D_L2m from the respective local language L₂₁ - L_2m into the global language G₂, thereby facilitating the communication between the user U and the automation devices 22 - 22_m. In particular, the translation of the local operational data D_L21 - D_L2m into the global language G₂ is performed according to at least one of the domain models 25i - 2 .

Fig. 3 shows an embodiment of an automatic system. Automation devices 32i - 32_k are arranged at different automation system levels 34i - 34₄. In particular, the automation system levels 34i - 34₄ are hierarchically

arranged, i.e. arranged in different automation system levels on top of each other such that an upper automation system level controls one or more underlying automation system levels. Accordingly, the uppermost automation system layer 34i controls the rest of the automation system levels 34₂ - 34₄, the automation system level 34₂ controls the automation system levels 34₃, 34₄, and the automation system level 34₃ controls the lowermost automation system level 34₄.

The access interface 31 is configured to receive a query 13 from the user U, and translate the query 13 according into the global language G3 as to enable communication between the user U and the automation devices 32i - 32_k.

Domain models 35i - 35₄ are provided to the access interface 31, wherein each of the domain models 35i - 35₄ describes, specifies and/or defines the automation system levels 34i - 34₄, respectively. In particular, the domain models 35i - 35₄ are configured to describe the automation system levels 34i - 34₄ using the global language G3. In particular, the lowermost automation system level 34₄ represents a field level, e.g. production and/or

manufacturing level, comprising any units and/or devices that are involved in a production and/or manufacturing process. For example, the field level includes production units, manufacturing devices, production line, sensor devices, valve devices, motors, gear units and/or conveyor belts.

The automation system level 34₄, i.e. the field level, comprises a robot arm 32₁₀, a sensor unit 32_llr gears 32₁₂, a valve unit 32₁₃, a conveyor belt 32₁₄, a motor 32_k, etc. Each of the automation devices 32₁₀ - 32_k is provided with a local storage unit and a local processing unit, wherein the local processing unit can generate local operational data and convert the local operational data into global operational data by translating into a global language G3 according to a domain model 35₄ that describes a domain of the automation system level 34₄ of the automation system 30. The local operational data can either be stored in the local storage unit and/or submitted to the access interface 31 by the respective automation device 32₁₀ - 32_k, i.e. self-submitted .

The automation system level 34₃ comprises control units, in particular for controlling the automation devices 32₁₀ - 32_k of the field level 34₄. Accordingly, the automation system level 34₃ acts as a direct/local control level. The

automation system level 34₃ comprises a programmable logic controller (PLC) 32₅, an input/output device 32₆, a local control gateway 32₇, a human-machine-interface (HMI) 32₈, and, additionally, a variable-frequency drive (VFD) , an actuator, a servomotor, a proportional-integral-derivative (PID) controller, a memory chip controller (MCC) and a radio- frequency identification (RFID) device that are not shown in Fig. 3.

The automation system level 34₂ combines a data acquisition level, an information output level, a supervisory level, a manufacturing execution level and a data analysis level. In particular, the automation system level 34₂ corresponds to a supervisory and data acquisition (SCADA) system level

combined with a manufacturing execution system (MES) level. The automation system level 34₂ comprises control and

operational device, preferably having a user interface.

Accordingly, the automation system level 34₂ comprises a mobile user interface 32₂, a terminal 32₃, a database server 32₄, and additionally a data warehouse, an application server, a corporate plant, a quality and downtime analysis client, a remote client, a web and/or alarm server that are not shown in Fig. 3. The automation devices 32₂ - 32₄ are translated into the global language G3 according to the domain model 35₂. In particular, the analysis data and/or the database inquiries from the automation devices 32₂ - 32₄ are translated into the global language G₃ using the domain model 35₂.

The automation system level 34i comprising a central control unit 32i is arranged on top of the hierarchical arrangement of the automation system levels 34i - 34₄. The automation system level 34i acts as an enterprise resource planning, business logistics, operational management, production scheduling and business analytics system level. In

particular, the automation system level 34i comprises a computer center, an analysis plant and/or corporate plant for analyzing, operating and/or organizing data, plant, business, enterprise. Further, the automaton system level 34i can comprise a plurality of central control units, computer systems, analysis clients, terminals with a user interface, gateways and/or central databases/data warehouses.

In particular, the automation system level 34i can deploy a query including analytic tasks to the underlying automation systems 34₂ - 34₄. Here, the query is communicated to the access interface 31. The domain model 35i, which is

associated with the automation system level 34i, describes the automation system level 34i using the global language G₃. The query is translated from the local language of the automation system level 34i into the global language G3. In particular, if the central control unit 32i represents the user U inputting a query, the domain model 35i can further contain analytics models for translating the query into the global language G₃.

The access interface 31 facilitates the communication between the user and the automation devices 32i - 32_k of the

automation system 30.

Fig. 4 shows a further embodiment of an automatic system 40.

The automation system 40 comprises an access interface 41 and a plurality of automation devices 42i - 42₄. The automation devices 42i - 42₄ can be assigned to different automation system levels from Fig. 3.

The automation device 42i includes a robotic arm 43, a processing unit 44 and a local data storage 45 that are communicatively coupled to one another. The robotic arm 43 is configured to generate and transmit local operational data to the processing unit 44 and to the local data storage 45. In particular, the robotic arm 43 is provided with a sensor device that determines local operational data, e.g.

temperature, workload, voltage, etc., of the robotic arm 43.

The processing unit 44 is configured to translate the local operational data received from the robotic arm 43. The processing unit 44 is configured to transmit the global operational data to the access interface 41 and to the local data storage 45. In particular, the processing unit 44 translates the local operational data from a local language that is associated with the robotic arm 43 into a global language G₄ of the automation system 40.

The automation device 42i may lack a processing power and/or a storage capacity. In this case, an additional processing unit and/or data storage unit can be provided, for example by inserting an external processing/storage device (e.g. a USB device) .

The automation device 42₂ comprises a sensor device 46 communicatively coupled with a mobile computer 47. The sensor device 46 is configured to measure a local operational data, e.g. a temperature, a voltage, a resistance, etc., of another automation device and output them as the local operational data. The mobile computer 47 is configured to output results from the measurements by the sensor device 46, translate the results into the global language G₄, thereby generating global operational data, and store the global operational data, together with the local operational data, in a local data storage of the mobile computer 47. The mobile computer 47 is further configured to transmit the global operational data to the access interface 41.

The automation device 42 includes a human-machine-interface 48i for input and output of queries and data, a processing unit 48₂ for translating the queries and data into a global language G₄ and a database 48₃ for storing data, e.g.

business-relevant indexes, performance parameters, etc. The automation device 42₃ can be classified as an enterprise resource planning system, a manufacturing execution system, a supervisory and data acquisition system or a combination thereof .

The automation device 42₄ comprises a set of multiple PLCs, a distributed control system, a process control system

including a plurality of input and output devices. The automation device 42₄ is configured to control and/or operate at least one automation device at the field level comprising production and/or manufacturing units. The automation device 42₄ can be assigned to a direct/local control level in combination with a supervisory control level.

Fig. 5 illustrates an embodiment of operation of an automatic system 50. The user U inputs the query 13 into the abstraction layer 51. The abstraction layer 51 is provided with domain model 53i, "Brewery . owl" in Web Ontology Language (OWL) and an analytics model 53₂, "Decision Tree", wherein both domain model 53i and the analytics model 53₂ are formulated in an ontology-based global language G₅. The ontology-based global language G₅ provides a global vocabulary and ontologies defining

automation devices 52i, 52₂ according to the domain model 53i. In particular, the ontology-based global language G₅ provides vocabulary such as "failure events", "heat", "workload" etc.

The query 13 is translated into the ontology-based global language G₅ according to the analytics model 53₂ and divided into sub-queries 13i, 13₂ according to the structure of the automation devices 52i, 52₂. The sub-queries 13i, 13₂ are then forwarded towards the automation devices 52i, 52₂,

respectively. In mapping processes 55i, 55₂, the sub-queries are translated into the respective local language L₅₁, L₅₂ of the automation devices 52i, 52₂.

The sub-query 13₂, e.g. an access request to multiple

databases for calculating a key performance index, may require another division of tasks, e.g. by branching-off the sub-query 13₂ into multiple tasks (e.g. interrogation of databases) and distributing the tasks to multiple nodes. In this case, a pre-mapping process 56 is required to adapt the multiple tasks to the corresponding nodes. A sensor device 52^ and a control unit 52₂ are

communicatively coupled to the abstraction layer 51. For example, the sensor device 52i is configured to provide a non-persistent data stream of measurements, /i.e. time series of data in a specific time interval, as the local operational data D_L51 and convert them according to the domain model 53i in a mapping process 54i into global operational data D_G51 that are compatible to the ontology-based global language G₅. The sensor device 52i either self-submits the global operational data D_G51 to the access interface 51 or it generates and transmits the global operational data D_G51 in response to the received translated query 55i. The automation device 52₂ comprises a programmable logic controller 57 and a database 58 having a historian. The programmable logic controller 57 is configured to feed the database 58 with data and to access the stored data. The incoming query 13₂ is converted into translated query 55₂ by being translated into the local language L₅₂ in a mapping process 54₂. The translated query 55₂ is executed by the programmable logic controllers 57 which accesses the database 58 accordingly and acquires the requested data as local operational data D_L52.

The local operational data D_L52 are converted into global operational data D_G52 by being translated into the ontology- based global language G₅ in the mapping process 54₂ and transmitted to the abstraction layer 51. In the further mapping process 56, the global operational data D_G52 merge with global operational data from other nodes into a response to the sub-query 13₂.

Although this disclosure describes the subject matter in accordance with preferred embodiments, it is obvious for the person skilled in the art that modifications are possible in all embodiments.

Claims

Patent claims

1. A method for operating an automation system (30)

including a plurality of automation devices (12₁ - 12_n) , the method comprising the steps of:

providing an access interface (11) for communicating a query (13) to at least one automation device (12i - 12_n) of the plurality of automation devices (12i - 12_n) , wherein the query (13) is communicated in a global language (Gi) ;

generating local operational data (D_L11 - D_Lln) associated with the at least one automation device (12i - 12_n) , wherein the local operational data (D_L11 - D_Lln) are generated in a local language (L_u - L₁₄) ;

converting the local operational data (D_L11 - D_Lln) into global operational data (D_G11 - D_Gln) by translating the local operational data (D_L11 - D_Lln) from the local language (Lu - Lin) into the global language (Gi) ; and

returning, in response to the query (13) , the global operational data (D_Gn - D_Gi_n) converted from the local

operational data (D_Ln - D_Li_n) associated with the at least one automation device (12i - 12_n) through the access interface (11) .

2. The method of claim 1, wherein

the global language (Gi) is an ontology-based language

(Gont) ·

3. The method of claim 1 or 2, further comprising the step of:

generating, by the at least one automation device (12i -

12_n) , the local operational data (D_Ln - D_Li_n) associated with said automation device (12i - 12_n) in the global language (Gi) as the global operational data (D_Gn - D_Gi₄) .

4. The method of claim 3, further comprising the step of: storing, by the at least one automation device (12i - 12_n) , the global operational data (D_Gn - D_Gi_n) in a local storage unit.

5. The method of claim 3 or 4, further comprising the step of:

submitting, by the at least one automation device (12₁ - 12_n) , the global operational data (D_G11 - D_Gln) to the access interface (11) .

6. The method of any of claims 1 - 5, further comprising the steps of:

providing at least one domain model (25i - 25±) for characterizing the at least one automation device (22i - 22_m) , wherein the at least one domain model (25i - 25 ±) is provided in the global language (G₂) ; and

converting the local operational data (D_L2i - D_L2m) into global operational data (D_G21 - D_G2m) according to the at least one domain model (25i - 25 ±) .

7. The method of any of claims 1 - 6, further comprising the steps of:

providing at least one analytics model (26i - 26_j) for characterizing the query (13); and

translating the query (13) into the global language (Gi) according to said analytics model (26i - 26_j ) .

8. The method of any of claims 1 - 7, further comprising the step of:

simultaneously communicating a plurality of queries (13) to a plurality of automation devices (12i - 12_n) .

9. The method of any of claims 1 - 8, further comprising the steps of:

planning a process (P) required for carrying out the query (13) ; and

executing the process (P) for carrying out the query (13) .

10. The method of any of claims 1 - 9, further comprising the step of: converting, in an abstraction layer (A) , the local operational data (D_L11 - D_Lln) into global operational data (D_Gii - D_Gin) by translating, in the abstraction layer (A) , the local operational data (D_L11 - D_Lln) from the local language (L_u - Lin) into the global language (Gi)

11. An automation system (30) comprising:

a plurality of automation devices (32₁ - 32_k) ; and an access interface (31) ,

wherein at least one automation device (32₁ - 32_k) of the plurality of automation devices (32₁ - 32_k) is configured to generate and to submit global operational data (D_G3i - D_G3k) to the access interface (31) ; and

wherein the access interface (31) is configured to communicate with said automation device (32i - 32_k) .

12. The automation system of claim 11, wherein the automation system (30) is configured to perform the method of any of the claims 1 - 10.

13. The automation system of claim 11 or 12, wherein the access interface (31) includes:

a user interface device (23) for receiving the query (13) ;

a planning unit (27) for planning a process (P) required for carrying out the query (13) ; and

an execution unit (28) for communicating the query (13) to the plurality of automation devices (12i - 12_n) and for executing said process (P) .

14. The automation system of any of claims 11 - 13, wherein the plurality of automation devices (32i - 32_k) are

hierarchically arranged in a plurality of automation system levels (34i - 34₄) including a field level (34₄) , a direct control level (34₃) , a data acquisition level (34₂, 34₃) , an information system level (34₂) , a data analysis level (34₂) and/or an enterprise resource planning level (34i) .

15. An automation device (42i) , comprising,

a data acquisition unit (43) configured to generate local operational data (D_L41) associated with the automation device (42i) , wherein the local operational data (D_L41) are generated in a local language (L₄₁) ;

a storage unit (45) configured to store the local

operational data (D_L41) ; and

a translation unit (44) configured to convert the local operational data (D_L41) into global operational data (D_G41) by translating the local operational data (D_L41) from the local language (L₄₁) into a global language (G₄) .