Method for Operating an Automation Device and Automation Device

Abstract

A method for operating an automation device including at least one real automation unit for controlling a technical process, an operator station for operating and observing the technical process to be controlled, an engineering system and virtual automation units which each simulate functions of a real automation unit and is stored on a server, wherein suitable measures are used to particularly simplify the start-up of the automation device, where a suitable distribution of the virtual controllers or automation units on servers to a large extent guarantees real-time behavior of the automation device.

Claims

1. A method for operating an automation device comprising at least one real automation unit for controlling a technical process, an operator station for operating and observing the technical process to be controlled, an engineering system and virtual automation units which each simulate functions of a real automation unit and is stored on a server, wherein the at least one real automation unit and the virtual automation units each comprise system functions, the method comprising: configuring process objects for other system functions via the engineering system and a system function of the system functions and monitoring a system function of other system functions with respect to utilization of a respective automation unit via the engineering system and the system function of the system functions; processing a first configured number of the process objects on the respective automation unit via the other system functions, exchanging a second configured number of the process objects between the respective automation unit and the operator station via the other system functions, and exchanging a third configured number of the process objects between the respective automation unit and the further automation units via the other system functions; and transferring a virtual automation unit to a further server in an event of the system function on the virtual automation unit of the virtual automation units identifying that the utilization of the respective other system function has reached or exceeded a threshold value, this.

2. The method as claimed in claim 1, further comprising: transferring a plurality of process objects of the at least one real automation unit is transferred to a further real automation unit for processing in the event of the one system function of the one system function on the at least one real automation unit identifying the utilization has reached or exceeded a threshold value.

3. An automation device comprising: at least one real automation unit for controlling a technical process; an operator station for operating and observing the technical process to be controlled; an engineering system; and virtual automation units which each simulate functions of a real automation unit and is stored on a server; wherein the at least one real automation unit and the virtual automation units each comprise system functions; wherein the engineering system and a system function of the system functions are configured to process objects and the system function is further configured to monitor other system functions with respect to utilization of a respective automation unit; wherein the other system functions are configured to process a first configured number of the process objects on the respective automation unit, exchange a second configured number of process objects between the respective automation unit and the operator station, exchange a third configured number of the process objects between the respective automation unit and further automation units; and wherein the automation device is configured to transfer a virtual automation unit of the virtual automation units to a further server in an event that utilization of the respective other system functions has reached or exceeded a threshold value is identified via the system function on the virtual automation unit of the virtual automation units.

4. The automation device as claimed in claim 3, wherein the automation device is further configured to transfer a plurality of process objects of the at least one real automation unit to a further real automation unit for processing in the event that the utilization has reached or exceeded the threshold value is identified via the one system function on the at least one real automation unit.

5. A virtual automation unit configured for an automation device as claimed in claim 3.

6. A virtual automation unit configured for the automation device as claimed in claim 4.

7. An automation unit configured for the automation device as claimed in claim 3.

8. An automation unit configured for the automation device as claimed in claim 4.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The invention and the embodiments and advantages thereof are described with reference to the drawing illustrating an exemplary embodiment of the invention, in which:

[0016] FIGS. 1 to 3 show automation devices in accordance with the invention; and

[0017] FIG. 4 is a flowchart of the method in accordance with the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0018] Identical parts depicted in FIGS. 1 to 3 are given the same reference characters.

[0019] In FIG. 1, reference numeral 1 designates an automation device comprising a real automation unit 2 connected by a field bus 3 to a decentralized peripheral unit 4. This decentralized peripheral unit 4 is provided with an interface assembly and with a plurality of process-input and process-output assemblies, where sensors are connected to the respective process-input assemblies and actuators are connected to the respective process-output assemblies. For purposes of simplicity, the present example only depicts a real configuration 5 of real automation components (automation unit 2, decentralized peripheral unit 4, etc.). An automation device of this kind typically comprises a plurality of such automation components to control a technical process or to solve an automation problem. The automation device 1 further comprises an engineering system 6 for planning, configuring and parameterization of the automation device 1 and an operator station 7, which enables an operator to monitor and control the process in a comfortable and safe way. If required, the operator can intervene in the course of the process for control purposes, which means that the operator can control and observe the technical process to be controlled by the automation device 1. The operator can use a client 8, which is typically a component of the operator station 7 and/or the engineering system 6, to access the planning software of the engineering system 6 and/or the control and observation software of the operator station 7 via a terminal bus 9 for reading or writing purposes. Therefore, in the present example, the client 8 represents both an operator station (OS) client and an engineering system (ES) client. The engineering system 6, the operator station 7, a server 10 and the automation unit 2 are connected to a further bus, i.e., a system bus 11. The server 10 represents a simulation server upon which virtual automation units 12, 13, 14 are stored. These virtual automation units 12, 13, 14 represent real automation units and are implemented in the form of software. In other words, the functioning principle and mode of operation of real automation units are simulated via the virtual automation units 12, 13, 14, where the server additionally simulates virtual decentralized peripherals and sensors and actuators, which are in operative connection with the simulation automation units 12, 13, 14, which is shown as a virtual configuration 15 in the drawing. Due to the fact that the automation device 1 is provided with both real and virtual automation components, this automation device 1 represents a mixed configuration which, within the context of a start-up or within the context of a system extension or an extension of the automation device, has to satisfy real-time requirements.

[0020] In order to satisfy these requirements, in particular within the context of a start-up of the automation device, each of the real and virtual automation units 2, 12, 13, 14 comprises a plurality of system functions. A system function, called a monitoring and control system function, and the engineering system 6 can be used to configure and parameterize process objects, where in addition, during the control operation, this monitoring and control system function monitors the other system functions with respect to utilization of the respective automation unit and the respective virtual automation unit. During an engineering phase, the process objects are determined in accordance with the automation problem to be solved and simulated automation problem to be solved, where the automation problem to be solved is usually pre-specified with references to plans, or invitations to tender.

[0021] A first number of these process objects are configured for the process control, where these process objects are stored on the real automation unit 2 and the virtual automation units 12, 13, 14. Each of these automation units 2, 12, 13, 14 solves a part of the automation problem or simulated automation problem as a result of which the configured process objects stored on the different automation units 2, 12, 13, 14 are different. A second number of the process objects are configured for communication between the respective automation unit 2, 12, 13, 14 and the operator station 7, 8 and a third number of the process objects are configured for communication between the automation units 2, 12, 13, 14.

[0022] FIG. 2 shows system functions 16, 17, 18, 19 for the real automation unit 2 and for the virtual automation unit 12 of the automation device 1, where the system function 16 is formed as a monitoring and control system function and wherein it is assumed that the virtual automation units 12, 13, 14 are setup and stored on the server 10. In FIG. 2, arrows 20 indicate the communication between the respective automation units 2, 12 and the OS-station 7, 9 and arrows 21 the communication between the automation units 2, 12, etc.

[0023] The system function 17 (communication between automation unit and operator station; AS-OS communication) generates a computing load on the respective automation units 2, 12, 13, 14 by processing the (AS-OS communication) process objects relevant for the operation and observation of the respective unit 2, 12, 13, 14 by the operator station.

[0024] The system function 18 (communication between the automation units 2, 12, 13, 14; AS-AS communication) processes AS-AS communication process objects on the respective unit. As a result, a computing load caused by the communication or data exchange between the units is generated on the respective unit 2, 12, 13, 14.

[0025] With the system functions 19 (processing), the processing of the process objects provided to control the technical (sub)process on the respective automation unit 2, 12, 13, 14 causes the generation of a computing load on the unit. The OS clients 8 also display the utilization or loading of the system functions 17, 18, 19, which are monitored by the system function 16 (monitoring and control). In the present exemplary embodiment, the utilization of the respective system functions 17 (AS-OS communication) of the real automation unit 2 and the virtual automation unit 12 are displayed on the OS client 8. It should be understood the loading of the further system functions 18, 19 can also be displayed on the OS client 8. In the event of the system function 16 of the virtual automation unit 12 identifying that the utilization or loading of the system function 17 has reached or exceeded a threshold value as a result of which the pre-specified processing cycle of automation device 1 is exceeded or the real-time behavior of the automation device 1 is no longer guaranteed, the virtual automation unit 12 is then transferred to a further server 22 (FIG. 3). It should be understood the virtual automation unit 12 is also transferred to the further server 22 if the system function 16 identifies that the utilization or loading of the system function 18 or 19 has reached or exceeded a threshold value because, once again, with overloading of this kind, real-time behavior of the automation device 1 is no longer guaranteed.

[0026] The transfer of a virtual automation unit 12, 13, 14 can occur via the system function 16 of the overloaded, virtual automation unit 12, 13, 14. The system function 16 automatically transfers the overloaded automation unit 12, where, to this end, this system function 16 and the server 22 are provided with suitable “transfer” software. It should be understood the transfer can also be performed by the engineering system 6, where the system function 16 displays to the engineering system 6 any overloading on the basis of which the engineering system 6 implements the transfer to the server 22.

[0027] The measures described enable the “calibration” of the virtual automation units, where the following procedure is preferred:

[0028] the virtual automation units are initially “placed” on a server,

[0029] the execution of the respective monitoring and control system function causes the execution of respective other system functions on the respective virtual automation unit to be monitored,

[0030] in the case of a cycle-time violation or an insufficient cycle-time reserve of one of the virtual automation units, this unit is transferred to a further server,

[0031] d) steps b) and c) are repeated until the real-time capability of the automation device is achieved.

[0032] If the real-time capability of the automation device has been achieved, the virtual automation units can be replaced by real automation units.

[0033] FIG. 4 is a flowchart of a method for operating an automation device 1 comprising at least one real automation unit 2 for controlling a technical process, an operator station 7 for operating and observing the technical process to be controlled, an engineering system 6 and virtual automation units 12, 13, 14 that each simulate functions of a real automation unit and is stored on a server 10, where the automation unit 2 and the virtual automation units 12, 13, 14 each comprise system functions 16, 17, 18, 19.

[0034] The method comprises configuring process objects for other system functions 17, 18, 19 via the engineering system 6 and a system function of the system functions 16 and monitoring a system function 16 of the other system functions 17, 18, 19 with respect to utilization of a respective automation unit 2, 12, 13, 14 via the engineering system 6 and a system function of the system functions 16, as indicated in step 410.

[0035] Next, a first configured number of the process objects on the respective automation unit 2, 12, 13, 14 is processed via the other system functions 17, 18, 19, a second configured number of the process objects is exchanged between the respective automation unit 2, 12, 13, 14 and the operator station 7, 8 via the other system functions 17, 18, 19, and a third configured number of the process objects is exchanged between the respective automation unit 2, 12, 13, 14 and the further automation units 2, 12, 13, 14 via the other system functions 17, 18, 19, as indicated in step 420.

[0036] Next, a virtual automation unit is transferred to a further server 22 in the event of the system function 16 on a virtual automation unit of the virtual automation units 12, 13, 14 identifying that the utilization of the respective other system functions 17, 18, 19 has reached or exceeded a threshold value, as indicated in step 430.

[0037] Thus, while there have been shown, described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.