WO2020084354A1 - Système et procédé permettant de tester des équipements industriels et de mettre automatiquement à jour un rapport de performance - Google Patents

Système et procédé permettant de tester des équipements industriels et de mettre automatiquement à jour un rapport de performance Download PDF

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Publication number
WO2020084354A1
WO2020084354A1 PCT/IB2019/050221 IB2019050221W WO2020084354A1 WO 2020084354 A1 WO2020084354 A1 WO 2020084354A1 IB 2019050221 W IB2019050221 W IB 2019050221W WO 2020084354 A1 WO2020084354 A1 WO 2020084354A1
Authority
WO
WIPO (PCT)
Prior art keywords
communication network
mobile device
industrial equipments
plc
operational parameters
Prior art date
Application number
PCT/IB2019/050221
Other languages
English (en)
Inventor
Rajmohan K
Ganesh J
Mahenth J
Kumar S
Original Assignee
Larsen & Toubro Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Larsen & Toubro Limited filed Critical Larsen & Toubro Limited
Publication of WO2020084354A1 publication Critical patent/WO2020084354A1/fr

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
    • G05B19/058—Safety, monitoring
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
    • G05B23/0267—Fault communication, e.g. human machine interface [HMI]
    • G05B23/0272—Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Definitions

  • the present embodiment relates to a system and method for testing industrial equipments in an industrial environment, and, more particularly relates to the system and method for automatic updation of a performance report and diagnosing error in the industrial equipments by seamlessly and simultaneously interfacing across the multiple secured networks.
  • Machine testing and commissioning primarily includes functional verification and I/O testing.
  • I/O testing Input devices e.g. proximity sensors, encoders and limit switches etc., and Output Devices e.g. solenoid valves, contactors and indication lamps etc., are verified by I/O module indications or by PLC program tags.
  • Functional testing Cylinders and Motors are actuated and their movements are checked as per desired function. Check Sheets are used to record the device status manually. On successful clearance of check sheet, testing completion status will be given.
  • the existing system and method for testing and commissioning of the machine/industrial equipments is manual which is not effective, accurate and also time consuming.
  • the object of the present embodiment is to provide a system which substantially overcomes the one or more of the above mentioned disadvantages.
  • the main object of the present embodiment is to provide a system and method for testing industrial equipments and automatic updation of performance report in an industrial environment.
  • the present embodiment also allows the user/operator to access the drawing sheets from a central server and diagnosis the industrial equipment in case of fault/error occurred while testing.
  • a system for testing industrial equipments and automatically updating a performance report and diagnosing fault is provided.
  • the system includes a Program Logic Controller (PLC), a control system and a mobile device.
  • PLC Program Logic Controller
  • the industrial equipments are adapted to sense and send operational parameters to the PLC.
  • PLC is adapted to control the one or more of industrial equipments based on the operational parameters.
  • the control system includes a Human Machine Interface (HMI) which is connected to the PLC in order to test each of the one or more of industrial equipments and a database to store (i) threshold value for each industrial equipments and (ii) the performance report of each industrial equipments.
  • HMI Human Machine Interface
  • the mobile device is connected (i) to the control system through a first communication network in order to access the Graphical User Interface (GUI) in the HMI, and (ii) to a central server through a second communication network.
  • GUI Graphical User Interface
  • the mobile device is adapted to seamlessly and simultaneously receive and transmit data from the first and second communication networks.
  • the mobile device is adapted to (a) access the GUI via the first communication network which has a control button for each of the one or more of industrial equipments (b) establish a secure communication with the central server for accessing a drawing sheet stored in the central server.
  • the operational parameters are read from the industrial equipment when a user triggers the control button in the GUI.
  • the performance report in the database is automatically updated when the operational parameters are within the threshold value and warning indication is displayed in the GUI when the operational parameters read from the industrial equipment is not within the threshold value, and upon displaying error indication, the user diagnose the industrial equipments by referring the drawing sheet corresponds to the industrial equipment.
  • the first communication network and the second communication network are different from each other.
  • the first communication network and the second communication network are internet, Wi- Fi etc.
  • the mobile device includes a first interface device for establishing communication with the first communication network and a second interface device for establishing communication with the second communication network.
  • the mobile device establishes the secure communication with the central server through a VPN tunnel established by a VPN router.
  • the drawing sheet is accessed at mobile device through the VPN tunnel and the drawing sheet cannot be copied or stored at the mobile device.
  • method for testing and diagnosing industrial equipments by a mobile device and automatic updation of a performance report includes steps of (i) establishing, by the mobile device, a communication with a control system through a first communication network, (ii) establishing, by the mobile device, a secure communication with a central server through a second communication network, (iii) accessing, by the mobile device, a Graphical User Interface (GUI) in the control system, (iv) triggering a control button at the GUI, (v) reading operational parameters of industrial equipment corresponds to the control button via a Program Logic Controller, (vi) updating a performance report when the operational parameters are within a threshold value, (vii) displaying a warning indication when the operational parameters are not within the threshold value; and (viii) diagnosing the industrial equipments with a help of the drawing sheet accessed via the central server.
  • GUI Graphical User Interface
  • Figure 1 illustrates a high level block diagram of a system for testing industrial equipments and updating a performance report stored in a central server in accordance to one embodiment herein;
  • Figure 2 illustrates a high level block diagram of a system as illustrated in Figure 1 with data-flow during testing of the industrial equipments in accordance to one embodiment herein;
  • Figure 3 illustrates a screen- shot of a Graphic User Interface of a control system in the system as illustrated in Figure 1 in accordance to one embodiment herein;
  • Figure 4 illustrates a flow diagram for method for testing industrial equipments by a mobile device and updating a performance report in accordance to one embodiment herein.
  • FIG. 1 illustrates a high level block diagram of a system 100 for testing industrial equipments 13, 14, 15 and 16 and updating a performance report stored in a central server 12 in accordance to one embodiment herein.
  • the system 100 includes a Program Logic Controller (PLC) 1, a control system 6 and a mobile device8.
  • PLC Program Logic Controller
  • the control system 6 incorporates a database and a Human Machine Interface (HMI) 4 which is connected to the PLC.
  • HMI 4 and database can be located away from the control system 6 and they can be connected to the control system 6 via wired/wireless connection.
  • the industrial equipments 13, 14 are adapted to sense and send operational parameters to the PLC 1.
  • the PLC 1 is a device made of electronic chips which will monitor and control the field devices e.g.
  • the industrial equipments 13, 14 are realized/implemented by Analog sensor and/or digital sensor.
  • digital Sensors 13 such as proximity, pushbuttons and limit switches etc. are sense the presence of the material and gives feedback to PLC 1 as a digital value.
  • analog sensors 14 such as Encoders, LVDT etc. are sense the motion of the material gives feedback as analog value.
  • Input module 2 and output module 3 are the interface between PLC 1 and the industrial equipments.
  • the input module 2 and output module 3 will do the analog to digital or digital to analog conversion i.e. A digital output of ‘1’ from PLC 1 is converted to 24V using output module 3.
  • the PLC 1 receives the operational parameters from the industrial equipments 13, 14 through an input module 2 and the PLC modifies the operational parameters of the industrial equipments 15, 16 through an output means 3.
  • the industrial equipments 13, 14, 15, 16 are connected to the input module 2 and output module 3 using various industry cables and wires.
  • the HMI 4 is a user interface for machine operation.
  • the HMI 4 has a Graphical User Interface (GUI) which indicates values of the operational parameters and status of the industrial equipments as well as control button in order to initiate the testing of the industrial equipments.
  • GUI Graphical User Interface
  • the control system 6 (for e.g., Laptop) having the database which stores the performance report associated to each industrial equipments as well as threshold value for the operational parameters associated to each industrial equipments.
  • Ethernet Switch 5 is a hub to connect Ethernet cables from various devices in order to establish Ethernet communication between connected devices.
  • the control system 6 is used for initial communication setting and program downloading in the PLC 1.
  • a router 7 is used to create a Wi-Fi medium of machine network as a cable from Ethernet Switch 5 is connected to it.
  • the Input Modules 2, Output Module 3, PLC 1, control system 6 and Router 7 are connected to an Ethernet Switch 5 through Ethernet Cable.
  • the mobile device 8 is a windows tablet which is connected to machine network through Internal Wi-Fi Adapter 9 (i.e. first interface device).
  • Internal Wi-Fi Adapter 9 is an electronic chip embedded to the mobile device’s mother board and it is used to connect to a Wi-Fi network.
  • the mobile device 8 is connected to the control system 6 through a first communication network i.e. the machine network.
  • the mobile device 8 is also connected to a central server 12 through a second communication network via an External Wi-Fi Adapter 10 (i.e. second interface device).
  • the External Wi Fi Adapter 10 is an electronic device which can be externally attached to the mobile device 8.
  • the external Wi-Fi Adapter 10 is used to connect the Mobile Device 8 to internet through which files from the central Server 12 can be accessed using secure VPN tunnel established by VPN Router 11.
  • the mobile device 8 is connected to machine network through Wi-Fi created by Router 7.
  • the PFC 1, Control system 6 and Mobile Device 8 are connected to the same network and the data transfer is possible between these devices.
  • the mobile Device 8 can be connected to internet using External Wi-Fi Adapter 10.
  • VPN Router 11 creates a secured path in the internet through which specific data from the central Server 12 can be accessed.
  • the Mobile Device 8 connected to both machine network and internet so it can access both machine devices and industry files.
  • the Mobile Device 8 is a centralized device which will monitor industrial equipments 13, 14 through GUI and update the performance report which includes device status in check sheets stored in the database.
  • the mobile device 8 also can access drawings stored in the central server 12.
  • the mobile device 8 can read/write PFC 1 data via the GUI and the control system 6, thereby it can monitor/control field devices (i.e. industrial equipments 13, 14, 15, 16).
  • the performance report in the control system 6 is automatically updated during testing operation performed in the Mobile Device 8.
  • Mobile Device 8 is connected to both machine network and internet so it can access drawings from local HMI 4 and industry Server 12.
  • the present embodiment adopts Web-HMI technology to accomplish testing, check sheet update and drawing sheet access.
  • a HMI program contains graphical interfaces will be loaded into HMI 4. Specific graphical interfaces can be assigned for testing, check sheet updation and drawing access based on user convenience.
  • the HMI 4 will convert the HMI pages in to web pages and it will host those web pages in machine network.
  • a web browser in the Mobile Device 8 can access those web pages as the Mobile Device 8 connected to machine network. Industrial equipments can be accessed, Check sheets can be updated.
  • the input module 2 When the industrial equipments 13, 14 senses the machine operation then the input module 2 will see a voltage at a point where industrial equipments 13, 14 connected to it. Presence of voltage can be identified by the indications at the input module 2.
  • the present embodiment uses Web-HMI graphical indications instead of module indications. Accordingly, the available voltage at the input module 2 will be converted to a digital value and this value gets updated in PLC I/O Tags.
  • the PLC I/O Tags are program variables assigned to I/O Modules. Graphical Interfaces in Web- HMI page can read this tags, thereby monitoring/testing operational parameters of the industrial equipments is achieved.
  • a group of predefined PLC tags are assigned to store the status of each industrial equipments. During testing specific graphical interfaces in Web-HMI can be used to update these predefined PLC tags i.e. when the user/operator triggers the control button displayed in the GUI at the mobile device 8 then the corresponding PLC tags are activated. At any point of testing these tag values can be retrieved to check sheets of the performance report automatically. These tag values are retrieved using PLC Communication Software installed in Control System 6.
  • the PLC Communication Software contains a group of drivers which are used to establish communication between PLC 1 and the control system 6.
  • the PLC tag values are fetched from PLC 1 to control system 6 using PLC Communication Software which is installed in the control system 6.
  • Dynamic Data Exchange Protocol is a real time data transfer protocol between two applications in this case it is between PLC Communication Software and Data Manipulation Software.
  • device status is recorded in check sheets. Check Sheets can be formatted as per user interest using Data Manipulation Software.
  • Figure 2 illustrates a high level block diagram of a system as illustrated in Figure 1 with data-flow during testing of the industrial equipments in accordance to one embodiment herein.
  • Figure 3 illustrates a screen-shot of a Graphic User Interface of the control system 6 in the system as illustrated in Figure 1 in accordance to one embodiment herein.
  • the GUI has five columns wherein first column includes the list of function associated to the industrial equipments, second column includes the name or identification of the industrial equipments in the industrial environment, third column is an indication column, fourth column includes control button to initiate/trigger testing operation, fifth column includes result buttons.
  • the GUI as shown in Figure 3 is displayed in the mobile device 8. When the user/operator triggers any one of the control button in the fourth column then the testing is performed for the function at the industrial equipment as defined in the first column and second column respectively at the corresponding row.
  • the control system 6 checks the value of operational parameter read from the PLC 1 with the corresponding threshold value associated to the operational parameters stored in the database. If the operational parameter read from the industrial equipment is within the threshold value then the indication button as shown in third column adapted to glow in green color. The control system 6 also adapted to update the performance report in the database with a predefined text (For example, “TESTED”). If the operational parameter read from the industrial equipments is not within the threshold value then the indication button as shown in third column adapted to glow in red color. The control system 6 also adapted to update the performance report in the database with a predefined text (For example,“FAILED”). In addition to automatic updation of performance report, the user/operator can also update the performance report manually using result button as shown in fifth column.
  • TESTED a predefined text
  • the user/operator can also update the performance report manually using result button as shown in fifth column.
  • the GUI also includes a button“Drawing sheet”.
  • the mobile device 8 retrieves the drawing sheet from the central server 12 pertain to industrial equipment which is selected at column 2.
  • the mobile device 8 securely interfaces with the central server 12 via the external Wi-Fi adapter 10.
  • the drawing sheet retrieved from the central server 12 is displayed in the mobile device 8 and the user/operator will refer the drawing sheets in order to confirm whether the connections between different field devices in the industrial equipments are accurate. Thus diagnosis the fault or error occurred during the testing process.
  • FIG. 4 illustrates a flow diagram 400 for method for testing industrial equipments by a mobile device and updating a performance report in accordance to one embodiment herein.
  • a communication with a control system 6 through a first communication network is established by the mobile device 8.
  • a secure communication with the central server 12 through a second communication network is established by the mobile device 8.
  • the GUI in the control system 6 is accessed by the mobile device 8.
  • the control button at the GUI is triggered by the operator/user.
  • operational parameters of industrial equipment correspond to the control button is read via a Program Logic Controller (PLC) (1).
  • PLC Program Logic Controller
  • the performance report in database is updated when the operational parameters are within a threshold value.
  • a warning indication is displayed in the GUI when said operational parameters are not within a threshold value.
  • the industrial equipments are diagnosed with a help of said drawing sheet accessed via the central server

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Human Computer Interaction (AREA)
  • Testing And Monitoring For Control Systems (AREA)

Abstract

L'invention concerne un système permettant de tester des équipements industriels, de mettre automatiquement à jour un rapport de performance et de diagnostiquer une défaillance. Le système comprend un automate programmable (AP), un système de commande et un dispositif mobile. Le système de commande comprend une interface homme-machine (IHM) qui est connectée à l'AP afin de tester chacun dudit ou desdits équipements industriels, et une base de données pour stocker (i) une valeur seuil pour chacun dudit ou desdits équipements industriels et (ii) le rapport de performance de chacun dudit ou desdits équipements industriels. Le dispositif mobile est connecté (i) au système de commande par l'intermédiaire d'un premier réseau de communication afin d'accéder à l'interface graphique utilisateur dans l'IHM, et (ii) à un serveur central par l'intermédiaire d'un second réseau de communication. Le dispositif mobile est conçu pour recevoir et transmettre en continu et en simultané des données provenant du premier réseau de communication et du second réseau de communication.
PCT/IB2019/050221 2018-10-26 2019-01-11 Système et procédé permettant de tester des équipements industriels et de mettre automatiquement à jour un rapport de performance WO2020084354A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201841040441 2018-10-26
IN201841040441 2018-10-26

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Publication Number Publication Date
WO2020084354A1 true WO2020084354A1 (fr) 2020-04-30

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1264221B1 (fr) * 2000-03-10 2005-08-31 Smiths Detection Inc. Commande d'un processus industriel au moyen d'au moins une variable multidimensionnelle
US20110231169A1 (en) * 2003-08-26 2011-09-22 Siemens Industry, Inc. System and Method for Remotely Analyzing Machine Performance

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1264221B1 (fr) * 2000-03-10 2005-08-31 Smiths Detection Inc. Commande d'un processus industriel au moyen d'au moins une variable multidimensionnelle
US20110231169A1 (en) * 2003-08-26 2011-09-22 Siemens Industry, Inc. System and Method for Remotely Analyzing Machine Performance

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