WO2021005542A1

WO2021005542A1 - Method and device for fault diagnosis and rectification for an industrial controller

Info

Publication number: WO2021005542A1
Application number: PCT/IB2020/056442
Authority: WO
Inventors: Raja Sivalingam; Kapil METHI; Dibya RANJAN PATTNAIK; Shankar Raman
Original assignee: Abb Schweiz Ag
Priority date: 2019-07-10
Filing date: 2020-07-09
Publication date: 2021-01-14

Abstract

The present invention relates to a method and device for fault diagnosis and rectification for an industrial controller of an industrial plant. The industrial controller is configured to display visual information associated with health of the industrial controller. A visual of the industrial controller is captured. The visual comprises indications from one or more indicators associated with at least one of a state and a type of the industrial controller. The values of the one or more indicators are compared with fault diagnosis information at a database, to identify the type and the state of the industrial controller. According to the state, a rectification action is identified from the database, and a communication is generated based on the rectification action. The communication is for rectifying the state of the industrial controller.

Description

METHOD AND DEVICE FOR FAULT DIAGNOSIS AND RECTIFICATION FOR AN

INDUSTRIAL CONTROLLER

FIELD OF THE INVENTION

[0001] The present invention relates to industrial controllers, and more specifically to fault diagnosis and rectification from faults for industrial controllers.

BACKGROUND OF THE INVENTION

[0002] Industrial plants have different devices for control and / or monitoring purposes. There are industrial controllers that can be control and / or monitoring devices. Such devices are used in various industrial processes. This involves having many modules (controller modules or units) that are used for different purposes from field communication, enterprise level functions etc.

[0003] Commissioning and maintaining these modules, requires domain skills and experience. There are some diagnostic tools available for maintenance. Existing diagnostic tools work only when a module is communicating over a communication network. The communication is used to gather and learn health diagnosis information. Thus, such tools introduce a constraint of having module availability (or connectivity).

[0004] These tools also lack in terms of offline monitoring and analyzing / recording health status in the absence of connectivity. Offline reports may be generated at the module (or connected device), to assist in fault diagnosis. These offline reports require physical presence of an expert to interpret the message (or report) and most often requires referring to a guide. Once offline messages are troubleshooted and modules are put back into normal operation, the expert may fail to record the resolution information. This would lead in missing offline report or audit trail.

[0005] Failure to record an audit trail causes difficulties for future references in term of tracing back similar problems and can increase device or process downtime. Even if such records are entered manually they are prone to human error and are only available for local use. [0006] Thus, when any controller goes into a non-communicable state, existing diagnostic tools and methods are not useful with missing or manual audit trails. The user (operator) needs to go through huge set of manuals and carry out physical inspection to solve the issue. It leads longer resolution time which also depends on domain experience.

[0007] In case of a site, there can be large number of modules, and troubleshooting information for different modules is needed for better inventory forecasting and maintenance scheduling.

SUMMARY OF THE INVENTION

[0008] The present invention relates to a method and device for fault diagnosis and rectification for an industrial controller. The industrial controller (or controller) can be a device in an industrial plant. The invention can be used for any controller of the plant.

[0009] The controller can have a display with one or more indicators. The controller is configured to display visual information associated with health of the controller. The controller is typically connected in a communication network of the industrial plant. There can be situations where there is a communication failure, and the controller is offline or not connected. In such situations, the controller is configured to display the visual information associated with the failure, fault or condition.

[0010] The invention utilizes such visual information or indication for fault diagnosis and rectification.

[0011] The method for fault diagnosis and rectification comprises capturing a visual of the industrial controller with a portable device having a camera. The visual can be an mage or a video. The visual comprises indication from one or more indicators associated with at least one of a state of the industrial controller, and a type of the industrial controller. [0012] Each indicator of the one or more indicators is one of a light indicator and a text indicator. The light indicator can be Light Emitting Diode (LED), Liquid Crystal Display (LCD) or other known light indicators. The text indicator can be a code or plain text The code can be a barcode, a Quick Response (QR) code and so forth. The plain text may be alphanumeric, numeric or text information.

[0013] Each indicator provides certain values or indications, which are available from the visual. For example, a text can be provided for controller type, an LED can be illuminated, non- illuminated, blinking (e.g. blinking sequence, frequency, intensity etc.) and so forth. Also, such indicators can be provided in different combinations and / or at different positions, for example there may be different indicators such as, light indicators, text indicators and so forth, different colored LEDs or LEDs at different positions on the controller and so forth. [0014] The values provided by the one or more indicators can be utilized for determining the type of the controller as well as the state of controller (or condition or fault). Accordingly, the method comprises comparing values (or indications) of the one or more indicators with fault diagnosis information at a database. The database has state or fault diagnosis information including a mapping of the one or more indicators with controller types and controller states. For example, which indicators) provides controller type and which indicator(s) provide controller state information can be already identified and mapped with corresponding indicator values. The database has the state information for different controller type. Thus, for a controller of one type, what indicators provide what values are available at the database, and these are mapped to controller conditions (faults or health states).

[0015] Thus, the comparison of the values can be used for identifying the controller type and the controller state. Accordingly, the method comprises identifying the state of the industrial controller from the comparison. Here, identifying the state comprises identifying the type of the industrial controller from value of a first indicator of the one or more indicators. Thereafter, the state of the industrial controller is identified using value of a second indicator of the one or more indicators, and the state information for the identified type of the industrial controller. [0016] Different indicators may be available for identifying the controller type and for the controller state. In an embodiment, the first indicator (or first set of indicators) is a text indicator. In accordance with the embodiment, the second indicator (or second set of indicators) is a light indicator. Thus, one or few indicators of the controller can assist in identifying the type of the controller, while one or some other indicators can assist in identifying the state. For example, the controller type can be provided in text, while an LED (or set of LEDs) provide state information. There could also (or alternately) be use of LEDs, LCDs, fault codes, and other suitable mechanism for displaying state information. [0017] Once the controller state (state of controller) has been identified, corrective actions can be performed. In other words, once it is detected why the controller (root cause) is in a particular condition (i.e. non-communicating or not sending data), a suitable corrective action can be performed.

[0018] The method accordingly comprises identifying a rectification action for the identified state. This can also be identified from the database, wherein the database further comprises a mapping of the fault states to rectification actions.

[0019] It is possible that the controller may be in a state which has not been defined in the database. Accordingly, in one embodiment, the method comprises detecting a new state for the industrial controller, from the value of the second indicator. This may involve capturing / prompting input for the controller state and receiving information in response to providing the prompt. In accordance with the embodiment, the method also comprises updating the database with information of the new state. This may involve prompting the operator for inputs in response to identifying the new state. Such inputs may automatically be recorded for updating the database. The operator might require assistance from an expert to provide a rectification for the new state. Such communication can be enabled and also recorded for the new state.

[0020] Once the rectification action is identified, a communication can be generated (e.g. to mitigate the fault). Accordingly, the method comprises generating a communication based on the rectification action. Here, wherein the communication is for one of a display interface and remote examination. The display interface can be that of the portable device, configured to render a sequence of steps for rectifying the state. The remote examination can be to check a configuration of the controller, to determine a configuration issue at the controller and resolve the configuration issue. This can be a communication to a remote server configured to perform the configuration check, where such server is connected to the portable device (e.g. over a communication network).

[0021] In an embodiment, the method also comprises storing information of the state and the rectification action. The information with regards to what caused the controller or communication failure can be stored for future reference. This can be used for example to create site survey reports, to resolve similar issue if faced for another controller of the same type and so forth.

[0022] Thus, when a controller in a plant or site faces a condition that is new for the type of controller, the troubleshooting information is utilized for rectifying the condition when faced in future by the same controller, or the controller at another location, site or plant. Even for known conditions, the troubleshooting information is automatically tracked and stored. This provides a summary to all the problems occurred since the controller was put into operation. Such summary provides problem history of the controller.

[0023] It is possible that the database can be local to one plant, in which case for such diagnosis (e.g. for new states), a central database may be updated, which can be referred to by various sites or plants.

[0024] In case of a site, site stock or inventory status is typically needed to plan inventory and schedule maintenance activities. For example, a service engineer may prepare list of all the system panels and list of modules including their counts. This is to ensure that there is minimum required spare of each type of modules.

[0025] In case for a site, the list of modules and their inventory status is not present, one would need to manually visit and prepare the list by filling the forms. This would involve lot of time and expertise. Also, one would later calculate the minimum required spare. [0026] The method in one embodiment utilizes the camera to identify all the modules mounted in a panel, and prepare the list of modules and their counts. In this case, service engineer or operator reads the panel using the camera, and the list of modules with their type and count is outputted. Once this data is ready for different panels, the minimum required spare can be calculated. For example, inventory of at least identified panels can be planned based on type of modules, number of modules, performance / troubleshooting information of the modules and so forth.

[0027] The method in one embodiment, is also utilized to generate warranty reports. In general, warranty expiration reports provide overall status about warranty of modules, which are typically created manually with data such as purchase date, expiry date and so forth. A service engineer or operator may not utilize the warranty information, while performing the troubleshooting.

[0028] As the present method enables having stock or inventory status, the information with regards to warranty can be added to the stocks. Such additional information can assist during troubleshooting, and in planning inventory and service.

[0029] Various steps of the method can be performed at the portable device, or some steps can be performed with the portable device and other steps at a server of the industrial plant In case of distributed solution, the portable device is configured to communicate with the server for the fault diagnosis and rectification.

[0030] In an embodiment, the method is performed with a device for fault diagnosis and rectification. The device is one of a mobile phone (e.g. smartphone) or other augmented reality (AR) based device (e.g. hollow lens). The device has camera configured to capture the visual of the industrial controller. The device also has the database comprising the fault diagnosis information. Alternately, the database may be at the server and accessible to the device (via a communication network). [0031] The device further has a fault diagnosis unit configured to compare values of the one or more indicators with fault diagnosis information at the database and identify the state of the industrial controller from the comparison. The fault diagnosis unit is also configured to identify a rectification action for the identified state from the database. In addition, the device has a communication unit configured to send a communication based on the rectification action, which can be generated with the fault diagnosis unit.

[0032] In an embodiment, the device additionally has a display interface to render a sequence of steps for rectifying the state. This can be a screen or an AR visualization through the AR device.

[0033] In place of having the fault diagnosis unit on the device, the fault diagnosis unit may alternately be provided on the server. In such case, the server receives the visual from the device, performs the controller type and controller state identification. Accordingly, the server can determine the required rectification action(s) and the same can be sent to be displayed on the display interface, through communication from the server to the device. This can involve providing visual (augmented) assistance for correcting the fault.

[0034] Depending on the rectification action, the server may initiate remote examination of a configuration of the controller, to determine a configuration issue at the controller and resolve the configuration issue. For example, an engineering or configuration tool can check the configuration of the controller. According to the check, corrections in configuration can be identified and pushed to the controller (e.g. via the device). This may require physical connection between the device and the controller (e.g. through a USB cable). Here, the device acts as the interface between the engineering tool and the controller. BRIEF DESCRIPTION OF DRAWINGS

[0035] Fig. 1 is a simplified diagram of an environment of an industrial plant with an industrial controller and a device for fault diagnosis and rectification for the industrial controller, in accordance with an embodiment of the present invention; [0036] Figs. 2a - 2c are simplified representations of visual indications provided by the industrial controller, in accordance with different embodiments of the present invention;

[0037] Fig. 3 is a block diagram of the device for fault diagnosis and rectification, in accordance with an embodiment of the present invention;

[0038] Fig. 4 is a flowchart of a method of fault diagnosis and rectification for the industrial controller, in accordance with an embodiment of the present invention; and

[0039] Fig. 5 is a simplified representation of a display interface displaying one of the measures for fault rectification, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0040] The present invention leverages capabilities of handheld, or augmented reality devices such as, but not limited to, smartphones, HoloLens and so forth, to provide hassle free handling of troubleshooting (diagnosis of faults / condition / state) and help rectify the identified problem. The present invention makes use of an optical instrument like camera (and optionally network connectivity capabilities) available in such devices to scan and process industrial controllers. This is used to easily identify problem at the controller, and immediately provide necessary troubleshooting information such as type of problem, root cause, resolution and the like. Also, information can be stored in the device, or shared with fingerprinting and other diagnostic tools over cloud/fog/Intemet of things (IOT) or other communication, eventually to be archived as part of audit trail. This makes future references for fault diagnosis and rectification hassle free.

[0041] In industrial environments, different types of diagnostic techniques are used to report problems and status of control and monitoring devices (controllers), which are used in various dynamic processes. One of the techniques is to place indicative components (indicators) that display - type and status of the module, which is visible to human naked eyes (i.e. without any AR devices). Such indicators could be light indicators, text indicators etc. For example, there can be series and/or combination of LEDs placed and indicating the status by ON/OFF, illuminating in particular/combination of color(s), blinking with different frequencies and sequences, having different intensity or brightness levels, and so forth, thus providing the status of module using physically mounted indicators. Typically, indicators are meant for local monitoring when remote diagnosis is not possible. One possible reason could be that the module (controller) is not reachable over a network making it difficult for remote diagnostic tools to reach the modules for monitoring and analysis purpose, thus usable only in online mode.

[0042] In general, industrial processes include different type of modules (or controller modules or units) having different physical appearances, dimensions, shapes, status indications using LED/LCD (or other light indicators) and/or labels (or other text indicators). Hence, it necessary to differentiate and identify the module type (controller type) using different possible identification techniques. These identification techniques can include techniques for recognizing and processing information with, but not limited to, QR code, barcode, image recognition, object identification (e.g. using Augmented RealityYVirtual Reality methods) and so forth.

[0043] As an alternative to having text / light indicators and techniques for utilizing the same, if the module (controller) is also configured to provide such information using a short- range communication, then the information may be obtained with such short range (or alternate communication channel). For example, RFID, or short-range protocols like Bluetooth, Zigbee and so forth, may be utilized as a redundant channel to provide indication of conditions.

[0044] The present invention implements one or more of the above-mentioned techniques to identify the controller (or module) type and provide problem statement along with possible solutions.

[0045] Referring now to Figure 1 , which shows an environment of an industrial plant (100) where the present invention may be practiced. The industrial plant has a communication network (102), which can include wired networks, wireless networks or a combination of wired and wireless networks. The communication network (102) acts as a gateway between industrial controllers such as industrial controller (101) and other plant devices such as a plant server (107). An industrial plant can have several industrial controllers or modules, which can be provided for controlling and / or monitoring one or more industrial processes (or parts thereof).

[0046] The industrial controller (101) is one such controller of the industrial plant (100) and is used as an example for describing the present invention. The controller (module) type is indicated through an indication on the controller. For example, a text indicator (first indicator or indicators) such as plain text as shown by 103b can be used to indicate the controller type. Alternately, a barcode, QR code or other suitable indicator may be provided for this purpose.

[0047] In normal operation, the industrial controller (or controller) is connected in the communication network. However, in certain scenarios, the controller may not be communicating. This can be due to a link failure, I/O issue, configuration error and so forth. The controller is configured to provide visual information (e.g. as indications) that can assist in identifying the exact issue that the controller is facing, and that can assist in rectifying (or mitigating the concern).

[0048] One or more indications (provided with second indicator or second indicators) provided by the industrial controller in different embodiments are shown in Figures 2a - 2c. Figure 2a shows one or more indications comprised of visual indications (103a) utilizing a plurality of light emitting diodes (LEDs) (light indicators). Figure 2b shows the indication in the form of error code comprised of text and numerals displayed on a screen associated with industrial controller. Figure 2c shows the indication provided by the industrial controller in the form of a text code (text indicator) on the industrial controller. In this embodiment the indication is provided as a barcode. But the text indicator can also be a QR code, a label or other text based indicator which provides information related to the fault.

[0049] In the embodiment of Figure 1, the one or more indications related to the state are visual indications (103a) provided by light indicators. The visual indications (information) are provided by a plurality of LEDs (106) each of which provides a visual indication. As shown in Fig. 1, an industrial controller may have LEDs such as R, F, A, B and five other LEDs that are shown using numbers from 1 to 5. The controller is configured to have the LEDs work according to different controller states (or conditions). For example, a healthy status of the controller can be indicated by illuminating LED‘R’ in GREEN, while the other LEDs (‘F’,‘A’, Ή’, and 1 - 5) are non-illuminating (i.e. OFF). Similarly, a fault (or faulty status) at the industrial controller can be indicated by illuminating LEDs‘R’,‘F’,‘A’ and 'B '‘in red, and LEDs 1 to 5 illuminating in combination of RED (or OFF) to indicate a type of fault.

[0050] A person skilled in the art will understand that the indication related to a fault at the industrial controller (e.g. controller fault, link failure etc.) can be shown by illuminating the plurality of LEDs in different combinations. As an example, LED at certain positions may be illuminated while others are non-illuminated; one or some LEDs blinking at certain frequency; utilizing LEDs of different colours, shapes etc. In place of combination of LEDs, other light indicators, text indicators or combination of light and text indicators may be used. Alternately, redundant communication (such as NFC, Bluetooth etc.) may be used if the controller supports such redundant communication.

[0051] The troubleshooting of the industrial controller is possible by observing and detecting the indication shown by such indicators.

[0052] The troubleshooting (fault diagnosis and rectification) is performed with a portable device such as a mobile phone, a Virtual Reality (VR) headset etc. The portable device comprises of an imaging unit (108) such as a camera.

[0053] Fig. 3 is a block diagram of a device that can be used for fault diagnosis and rectification for the industrial controller. This device can be a smartphone, other AR based device like Hololens, or other such devices that can capture visual of the controller and if required communicate with a remote device for the fault diagnosis and rectification.

[0054] As shown, the device has a processor (301), an imaging unit (108), a communication unit (302) and a fault diagnosis unit (306). The processor is configured to execute various steps involved in the fault diagnosis and rectification by utilizing the various modules, i.e. with the imaging unit, the communication unit, the fault diagnosis unit etc. These modules may be hardware components, or containerized modules, configured to execute logical steps required for carrying of the method.

[0055] The imaging unit can be a camera that can be used to capture an image or video of the controller. The image (or video) has the different indications or values (provided by the indicators). The fault diagnosis unit is configured to receive the image or visual information, from the imaging unit (108). The fault diagnosis unit is further configured to compare the received information with information stored in a database (305). This involves applying image analysis on the visual to detect the indications or values of the indicators.

[0056] The database is provided in a memory (304) of the device, or it is external to the device (e.g. cloud database) and accessible through a network (e.g. plant server). The database is created from historical information in relation to health assessment of different controllers. Further, the database includes initial configuration of the various controllers in the plant Thus, for various types of controllers, the database has information of where and how the controllers are configured, which indicators indicate what information for each controller and how are they mapped to various controller states. Thus, when references (indications) are available for one controller, the state can be identified. The controller type itself can be identified from the text label or other text code or indicator provided on the controller, which is also stored in the database.

[0057] Thus, the database running locally (for offline reason when connectivity is limited or not available) or referred from remote locations is used to analyze the problem with references (metadata or data generated from the visual). Once problem is identified with available reference data, details of problem, description of the problem, solution/remedy, or further actions to be done can be provided. Such information is also available in the database and once the problem or fault is identified, resolution can be identified and provided.

[0058] Accordingly, the fault diagnosis unit is configured to detect the fault (or condition) in the industrial controller with the comparison of the indications with information in the database. Furthermore, the fault diagnosis unit is configured to trigger a communication / or to display the root cause and recommend one or more measures to take to rectify the fault. The recommendations can include for example, checking certain ports of the industrial controller, performing configuration checks, restarting the industrial controller etc. [0059] The recommendations can be provided on a HMI (such as 104 shown in Fig. 1). This HMI if it is part of the same device, can receive the instructions for displaying the root cause / solution. Alternately a communication to render the solution (e.g. by performing certain sequence of steps) can be sent. Some situations may need executing certain additional steps. For example, the controller may show that there may be a configuration issue. In that case, the configuration would need to be checked / analyzed. Here the fault diagnosis unit sends a communication for executing such a configuration check at a plant server. Engineering or configuration systems having controller information can run the check, identify the issue and provide a fix for the problem, which may be pushed to the device. The device can be physically connected (e.g. with a cable) to correct the controller configuration.

[0060] The fault diagnosis unit can trigger storing information related to the fault and the one or more measures recommended, or the solution provided. This can be used for future purposes such as future fault rectification, creating site survey reports etc. These can be a life cycle report for the controller which provides summary of all the problems occurred in the controller since it was put into operation. Such report provides problem history of the controller.

[0061] There could be situations where the current state is not present in the database. For example, if a new type of fault is detected, then analysis information of the new fault and recommended measures taken to rectify the fault need to be stored in the database (305). This can be generated with support from the operator. Visual prompts may be provided, or the actions performed can be recorded (e.g. log data). Such data can be stored or archived for future use. Here, it may be stored locally or sent to a central / plant server for storage.

[0062] The stored data is used for subsequent fault detection in the industrial controller (101) (e.g. reoccurrence of the fault or occurrence of the fault for a controller of the same type at a different location). Alternately, the stored data for different controllers is used to create site information.

[0063] The device shown in Fig. 3 can perform the method steps (in total, or some of the method steps) involved in relation to the fault diagnosis and rectification. The following describes the method for fault diagnosis and rectification, in accordance with an embodiment of the present invention. [0064] Referring now to figure 4, which is a flowchart of the method (400) for the fault diagnosis and rectification in an industrial controller (such as 101), in accordance with an embodiment of the present invention. [0065] At 402, the method includes capturing a visual of the industrial controller with a portable device having a camera. The visual can be an image or a video. As mentioned above, the visual comprises one or more indications from one or more indicators associated. These indications are associated with a type of the industrial controller, or a state of the industrial controller. Thus, the device can capture an image or a video with the camera and the same can be analyzed to detect the controller type and the current state of the controller.

[0066] Accordingly, at 404, the method comprises comparing values of the one or more indicators with fault diagnosis information at a database (such as 305). As described above, the comparison of the values is used for identifying the controller type and the controller state. Accordingly, at 406, the method comprises identifying the state of the industrial controller from the comparison. Here, identifying the state comprises identifying the type of the industrial controller from value of a first indicator (e.g. text indicator). Thereafter, the state of the industrial controller is identified using value of a second indicator (e.g. LEDs), and the state information for the identified type of the industrial controller.

[0067] Once the controller state (state of controller) has been identified, corrective actions can be performed. In other words, once it is detected why the controller (root cause) is in a condition (i.e. non-communicating or not sending data), corrective action can be initiated or performed.

[0068] The method accordingly at 408 comprises identifying a rectification action for the identified state. This can also be identified from the database, wherein the database further comprises a mapping of the fault states to rectification actions. As described above, it is possible that the controller may be in a state which has not been defined in the database. Accordingly, in one embodiment, the method comprises detecting a new state for the industrial controller, from the value of the indicators. This may involve capturing / prompting input for the controller state and receiving information in response to providing the prompt. In accordance with the embodiment, the method also comprises updating the database with information of the new state.

[0069] Once the rectification action is identified, a communication can be generated (e.g. to mitigate the fault). Accordingly, the method at 410 comprises generating a communication based on the rectification action. Here, the communication is for one of a display interface and remote examination. The display interface can be that of the portable device, configured to render a sequence of steps for rectifying the state. The remote examination can be to check a configuration of the controller, to determine a configuration issue at the controller and resolve the configuration issue.

[0070] Figure 5 shows one method of displaying the detected fault and the recommended measures (actions) for rectifying the fault on the HMI. The various parameters associated with the fault such as the fault code, the current status of the industrial controller are displayed on the HMI. For example, the fault can be‘application segment violation’. The fault code could be‘14’, the status could be‘Fault detected’ and so forth. Such information are displayed on the HMI or display interface. Maintenance can be performed based on the solution displayed on the HMI. Visual assistance can also be provided to the operator for the maintenance. For example, in case of an issue with a port, such ports can be highlighted and brought to operator attention for easy rectification. [0071] The information with regards to what caused the controller failure can be stored for future reference. This can be used for example to create site survey reports, life cycle reports, warranty reports, or to resolve similar issue if faced for another controller of the same type. Accordingly, at 412, the method comprises storing the information with regards to the fault.

[0072] Thus, when a controller (or module) in a plant or site faces a condition that is new for the type of controller, the troubleshooting (fault diagnosis and rectification) information is utilized for rectifying the condition when faced in future. This can be for the same controller, or the controller at another location, site or plant. Even for known conditions, the troubleshooting information is automatically tracked and stored. This provides a summary to all the problems occurred since the controller was put into operation, for example in a life cycle report Such summary provides problem history of the controller.

[0073] It is possible that the database utilized for troubleshooting is local to the controller or one plant. In such case after diagnosis and rectification (e.g. for new states), a central database may be updated, which can be referred to by various sites or plants. This assists in troubleshooting for similar controllers in different locations, sites or plants.

[0074] In case of a site or a plant, site stock or inventory status is typically needed to plan inventory and schedule maintenance activities. For example, a service engineer may prepare list of all the system panels and list of modules including their counts. This is to ensure that there is minimum required spare of each type of modules. In case for a site, the list of modules and their inventory status is not present, one would need to manually visit and prepare the list by filling the forms. This would involve lot of time and expertise. Also, one would later calculate the minimum required spare.

[0075] The method in one embodiment, utilizes the camera to identify all the modules mounted in a panel, and prepare the list of modules and their counts. In this case, service engineer or operator reads the panel using the camera, and the list of modules with their type and count is outputted. Once this data is ready for different panels (across the site), the minimum required spare can be calculated. For example, inventory of at least identified panels can be planned based on type of modules, number of modules, performance / troubleshooting information of the modules and so forth.

[0076] The method in one embodiment, is also utilized to generate warranty reports. In general, warranty expiration reports provide overall status about warranty of modules, which are typically created manually with data such as purchase date, expiry date and so forth. A service engineer or operator may not utilize the warranty information, while performing the troubleshooting.

[0077] As the present method can enable having stock or inventor status, the information with regards to warranty can be added to the stocks. Such additional information can assist during troubleshooting, and in planning inventory and maintenance. For example, instead of resolving the action by way of maintenance, a new module may be placed (as warranty is expired).

[0078] The method and device disclosed herein has many advantages over conventional methods and devices employed for health assessment. The conventional methods require the service personnel (engineer or operator) to manually go to location of the industrial controller and observe the indication of the fault provided by the industrial controller, and after analysis detect the type of fault in the industrial controller. The service personnel or operator needs to refer user manuals of the industrial controller to rectify the detected fault. Most times, the fault, even if rectified, is not stored in any online database, thus future reference of the maintenance activity is not possible.

[0079] With the use of a device capable of detecting and rectifying the fault in the industrial controller, the efficiency and speed of fault detection and rectification is increased. Additionally, the invention enables solutions in cases where earlier solutions were not possible. For example, in case of new issues faced, the audit trail can be used for same type of controller at different locations. Furthermore, audit trails created for single controller or various controllers for the plant assist in effectively tracking controller health and managing plant assets. Site stock reports, life cycle reports and warranty reports are created for the various modules, which enhances the future troubleshooting as well as in planning and maintaining the different modules, thereby assisting to reduce downtime.

Claims

We claim:

1. A method for fault diagnosis and rectification for an industrial controller of an industrial plant, wherein the industrial controller is configured to display visual information associated with health of the industrial controller, the method comprising:

capturing (402) a visual of the industrial controller with a portable device having a camera, wherein the visual comprises indications from one or more indicators associated with at least one of a state of the industrial controller, and a type of the industrial controller, and wherein each indicator of the one or more indicators is one of a light indicator and a text indicator;

comparing (404) values of the one or more indicators with fault diagnosis information at a database, wherein the fault diagnosis information comprises a mapping of the one or more indicators with controller types and controller states;

identifying (406) the state of the industrial controller from the comparison, wherein identifying the state comprises:

identifying the type of the industrial controller from value of a first indicator of the one or more indicators; and

identifying the state of the industrial controller from value of a second indicator of the one or more indicators, and the fault diagnosis information for the identified type of the industrial controller;

identifying (408) a rectification action for the identified state from the database, wherein the database further comprises a mapping of the fault states to rectification actions; and

generating (410) a communication based on the rectification action, wherein the communication is for one of:

a display interface of the portable device, to render a sequence of steps for rectifying the state; and

remote examination of a configuration of the controller, to determine a configuration issue at the controller and resolve the configuration issue.

2. The method as claimed in claim 1, wherein identifying the state of the industrial controller comprises:

detecting a new state for the industrial controller, from the value of the second indicator; and

updating the database with information of the new state.

3. The method as claimed in claim 1, wherein the one or more indicators comprises a plurality of Light Emitting Diodes (LEDs), and wherein the state of the controller is identified from one or more of:

illumination status of each LED, wherein the LED is one of illuminated, non- illuminated and blinking;

an intensity of light of the LED;

a color of the LED; and

a position of the LED on the industrial controller.

4. The method as claimed in claim 1, wherein the first indicator is a text indicator and the second indicator is a light indicator.

5. The method as claimed in claim 1, wherein generating the communication comprises storing information of the state and the rectification action, wherein the information is utilized to generate one or more of a site stock report, a life cycle report and a warranty report.

6. The method as claimed in claim 1, wherein one or more steps of the method are performed with the portable device.

7. The method as claimed in claim 6, wherein at least one step of the one or more steps are performed with a server of the industrial plant, based on communication with the portable device.

8. A device (104) for fault diagnosis and rectification for an industrial controller (101) of an industrial plant, wherein the industrial controller is configured to display visual information associated with health of the industrial controller, the device comprising:

a camera (108) configured to capture a visual of the industrial controller, wherein the visual comprises indications from one or more indicators associated with at least one of a state of the industrial controller and a type of the industrial controller, and wherein each indicator of the one or more indicators is one of a light indicator and a text indicator; a database (305) comprising fault diagnosis information, wherein the fault diagnosis information comprises a mapping of the one or more indicators with controller types and controller states;

a fault diagnosis unit (306) configured to:

compare values of the one or more indicators with fault diagnosis information at the database;

identify the state of the industrial controller from the comparison, wherein identifying the state comprises:

identifying the state of the industrial controller from value of a second indicator of the one or more indicators, and the fault diagnosis information for the identified type of the industrial controller; and

identify a rectification action for the identified state from the database, wherein the database further comprises a mapping of the fault states to rectification actions; and a communication unit (302) configured to generate a communication based on the rectification action, wherein the communication is for one of:

a display interface (110) to render a sequence of steps for rectifying the state; and

9. The device as claimed in claim 8, wherein the device comprises the display interface.