Patent Abstract:
This invention relates to the Life Cycle Management System for distributed Intelligent Electronic Devices (IED) starting from the design phase to the end of service phase. Hence, it caters to the needs from installation via engineering, installation/commissioning phases, until asset management and remote service support of the devices during the operational phase The increasing decentralization of the involved components via networks, especially via the Internet, is a key criterion and needs to be addressed by the life cycle management. The added value for the customer grows disproportionately with the degree of integration of multiple independent software components into a complex and often highly distributed control system. The architecture of today&#39;s control systems must be sufficiently flexible to allow customers to regard their plant components from various locations. Additionally, the stability, security and maintainability of such a system is strongly dependent on the homogeneity and interoperability of all involved components.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a continuation of pending International patent application PCT/IB2006/001381 filed on Jul. 11, 2006 which designates the United States and the content of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to life cycle management systems. More specifically, this invention relates to a life cycle management system (LCMS) that allows location-independent control of a plurality of devices within a process plant, by integrating information from asset monitors within the plant and all stages in the life cycle of the Intelligent Electronic Device. 
       BACKGROUND OF THE INVENTION 
       [0003]    The life cycle of any Intelligent Electronic Device (IED), also referred to as an asset, includes all the activities that start with design and engineering phases of the process plant application needing the device, going on to selecting a manufacturer and device to suit the application, the procurement and placement of the device into service, operating the device while it is deployed and culminating in retirement of the device from service. In the operational phase, the device is also managed and maintained to provide sustained and reliable service. 
         [0004]    IEDs provide services to Process Industries, Discrete Component Manufacturing Industries, Power Generation, Transmission and Distribution Utilities etc. Amongst the various stages in the life cycle of an IED, there exists a variety of device management and maintenance operations performed by process plant personnel and device vendors. The device vendors perform support of disparate devices using a diverse array of tools and systems, rendering great complexity to the overall operations within the plant. 
         [0005]    The complexity of today&#39;s systems stems from a variety of field bus standards, a number of diagnostic and maintenance tools for device management, backward compatibility requirements for several software versions necessitated in order to protect one&#39;s investment over time, several software versions of host application standards and the introduction of the Internet. For example, disparate industry standards for field bus networks in typical manufacturing plants could be any of ProfiBus, Device Net, Foundation Field Bus (for the Process Industries), Inter Bus S, Control Net and CAN Open (for the Discrete Manufacturing Industries). HART protocols need inclusion in this list even though they are not field bus protocols, as they present the same requirements towards a holistic LCMS. The disparate protocols mentioned have individual engineering tools to configure, install, commission and maintain devices that are connected using those protocols. 
         [0006]    Field bus networks have evolved over the last ten years and many of them remain viable for many more years to come. Customers are keen to protect the investment they have made on these devices and networks, consequently being required to maintain diverse engineering tools and skills to keep the overall system running. Simply reducing the number of allied standards does not readily translate to reduced complexity. In other words, a LCMS needs to consider and make provisions for obsolete standards in a consistent manner. 
         [0007]    At the present time, the players involved in the different stages in the life cycle of the devices in a process plant and the overall system in that plant are the design engineers, the device vendors offering support to the devices deployed, the control operator controlling the overall operation of the plant etc. The device vendors presently provide Electronic Device Description (EDD) source files written using the Electronic Device Description Language (EDDL) to standardize a simple operator control interface. This technology does not address the problems that the customer faces in coping with a diversity of vendor specific engineering tools to set up, configure, install, commission and perform the life cycle management of devices. The newer technology of Field Device Tool (FDT) and Device Type Manager (DTM), intended as an extension of the EDDL technology, has addressed this issue. This technology made it possible to have a common interface at the host systems to engineer and operate the field device networks with the field devices supplied by different vendors. This technology consequently increased the need for a LCMS owing to the large number software components, each having related and independent updates and upgrades, with respect to the host platform. Device vendors are often reluctant to shoulder the responsibility of providing DTMs for the devices which they supply, owing to the disparity in host platforms, changing software version releases for the underlying Operating Systems etc. Ethernet is now popular in process plant environments, and is rapidly evolving to accommodate an application subset that extends beyond hard real-time applications. This has further complicated the scenario. The emerging standards of ProfiNet, Ethernet IP and Ethernet for Control and Automation Technology (ECAT) are also responsible for introducing even more field devices. FDT/DTM tools are commonly unavailable for these devices utilizing the above-mentioned standards of ProfiNet, Ethernet IP and ECAT. Further, when there is a need to deploy EDDL and FDT/DTM technology concurrently, the complexity of the system increases further. 
         [0008]    With the Internet enabling greater access with respect to Engineering and Asset Management systems, which provide thin client applications, the need for synchronization and inter-operability with the core system is amplified. Furthermore, device vendors provide several remote services and a multitude of web library servers (for different bus protocols such as PNO, ProfiBus, HART etc.), also enabled by the Internet. The design paradigm is rapidly evolving towards increasing the role of the Internet in basic connectivity of devices and other operations on devices. 
         [0009]    Several Computerized Maintenance Management System (CMMS) packages (also known as Common Asset Management or Engineering Systems) are available for plant operators to choose from including IFCS, Maximo and SAP. These systems focus on Enterprise Application Integration and have limitations when it comes to integrating diagnostic information from devices deployed in the field. 
         [0010]    Plant operators have available to them a variety of desktop tools, hand-held devices and commercially available Personal Data Assistants (PDAs) to enable them to receive and analyze information pertaining to the devices in the plant. These tools and mobile devices encourage the engagement of web servers to relay the information enabling location-independence when it comes to managing the life cycle of the system. 
         [0011]    Common Asset Management or Engineering Systems referred to above have diverse customer interfaces for gathering such information, but do not have common Human Man-Machine Interfaces (HMMIs) for life cycle management information. This is because life cycle management implies control over a larger subset of tasks (including engineering design and documentation) having to do with field devices, as opposed to the CMMS or Common Asset Management or Engineering Systems. 
         [0012]    It is a major shortcoming of the existing systems to address the complexity introduced by the disparity in protocols, tools, implementation platforms, software versions and network configurations. 
         [0013]    PCT Patent WO 01/02953 discloses a Method of integrating an application in a computerized system, presenting a system for computerized control of a real world object, making allowances for interlinking objects systematically. This patent introduces the concept of Composite Objects, containing Aspects representing facets of real world objects. This concept of Aspects is utilized in the present invention, however, the present invention extends beyond systematic representation and computerized control, to providing a LCMS in the case of process plants. Incorporating information from several stages in the life cycle of a device is not explored in the PCT Patent, it only provides a mechanism to enable such incorporation. The LCMS proposed by the present invention is located on the control network to manage IEDs in such domains as Process Automation and Manufacturing Automation. The means for maintaining information for a device or product through its various life cycle stages is enabled by the concept of Aspect Views of real world objects, from several different perspectives, each perspective being defined as a piece of information and set of functions to create, access, and manipulate the information provided. These Aspect Views are the building blocks of the Device Integration Aspect Objects. 
         [0014]    U.S. Pat. No. 6,795,798 discloses a method for the Remote Analysis of process control plant data. This patent does not mention incorporating the documentation aspects within its design. Further, the central method of communication in the preferred embodiment uses XML. 
       SUMMARY OF THE INVENTION 
       [0015]    It is an object of this invention to provide a Life Cycle Management System that incorporates, utilizes and relays information in the engineering, installation/commissioning and operational phases of IEDs commonly used in process plants. Another object of this invention is to address the complexity in a highly distributed control environment. This is achieved using a combination of compatibility checks and version control checks, allowing customer-interactivity where desired and relevant. Another object of this invention is to use information aggregated in Device Integration Aspect Objects, organized by different Aspects pertaining to the life cycle of an IED in conjunction with information obtained from asset monitors in various physical process plants, serviced by the LCMS, to provide asset optimization within the process plants. Further, this invention seeks to provide such control and optimization in a location-independent fashion, making provisions for such distributed environments as enabled by the Internet. Device vendors can connect to the information made available by the LCMS in order to provide diagnostic support, without being physically present at the plant site. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  provides an overview of the LCMS framework. 
           [0017]      FIG. 2  shows the layout of an industrial plant 
           [0018]      FIG. 3  shows a modular overview of the various components in a Life Cycle Management System. 
           [0019]      FIG. 4  shows the stages in the Life Cycle of a device. 
           [0020]      FIG. 5  shows the details maintained in a Device Integration Aspect Object. 
           [0021]      FIG. 6  shows an Automation Object, also referred to as a Device Integration Aspect Object. 
           [0022]      FIG. 7  expands on the Documentation Aspect. 
           [0023]      FIG. 8  shows another feature of the LCMS, which involves version checking the overall system. 
           [0024]      FIG. 9  shows the bi-directional data exchange between the process engineering environment and the control system engineering environment. 
           [0025]      FIG. 10  shows the Asset Monitor Report, used to communicate device information. 
           [0026]      FIG. 11  shows the Asset Monitor status reports. 
           [0027]      FIG. 12  shows the Asset Condition Report. 
           [0028]      FIG. 13  shows the integration of the Internet in the process control systems. 
           [0029]      FIG. 14  shows the connectivity application provided to the vendor to enable location-independent diagnostics. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    The Life Cycle Management System of the present invention incorporates, utilizes and relays information in the engineering, installation/commissioning and operational phases of IEDs commonly used in process plants. Complexity in process plants are introduced by the diversity in field bus networks, network protocols, a number of diagnostic and maintenance tools for IED management, backward compatibility requirements for several software versions necessitated in order to protect one&#39;s investment over time, several software versions of host application standards and the introduction of the Internet. 
         [0031]      FIG. 1  provides an overview of the LCMS framework. The LCMS integrates standards such as the DD/EDD/CFI/TEDS store  1 , DTM Builder  2 , DTM Inspector  3 , Device communication FDTs  4  connected to several DTMs  5 . It further integrates various control technologies, for example, the Human Machine Interface (HMI)  6 , document managers  7 , control function designers  8 , field bus topology builder  9 , device management  10 , Asset Monitoring/optimization  11  and device integration package installation tool  12 . The interactions and data-flow between the modules detailed above are recorded and controlled by using a database server  13 , a data store  14 , a plurality of device connectors  15 , control connectors  16  and network connectors  17 , an Asset Management server  18 , a proxy server  19  (when required), and a web server  20  (when required). 
         [0032]      FIG. 2  shows the layout of a process plant  38 , connected to a Life Cycle Management System  25 . Within the process plant, there exists a number of sensor networks and smart transducers  30  and Field Devices, connected by networks such as Multiplexed EtherNet  31 , a HART signal bus  32 , ProfiBus  33 , ProfiNet  34 , CAN Bus  35 , InterBus S  36  and ASI Bus  37 . There exist one or a plurality of Operator Work Stations  26  which overlook the operations of the IEDs and networks. These networks, connecting the various IEDs, sensors, transducers etc., communicate with an IED Gateway  29  which in conjunction with a Network Communication Application Processor  28 , collects data from all the devices and relays them to the Life Cycle Management System  25 . The Life Cycle Management System  25 , communicates with a variety of external systems such as, Computer Based Management Stations  23 , Device Vendor Remote Service Stations  22 , Web Library Servers  21  providing updates for various IEDs and control networks via the Internet and an array of mobile devices  27  which can be sent information for remote control and maintenance of the plant by an operator. 
         [0033]    The stages in the life cycle of an IED include an engineering phase, an installation/commissioning phase and an operational phase. These phases have several sub-phases within them. In the Engineering Phase the actual design is carried out and relevant documentation is generated and collected, for future reference. Further, there exist several engineering sub-systems that need to be taken into account such as document managers for document administration, library assistants, reuse assistants, cross-reference tools and document import/export capabilities. In the Installation/commissioning Phase the physical location of the IED in the plant is defined in the drawings pertaining to layout of the IEDs in the plant. In addition, a set of drawings are made to define the installation/commissioning of the IED, its connection to the process on one end and on the other to the equipment in the control room via bus architectures, with details of installation/commissioning hardware (hubs/drop cables/couplers/power supply units). In the Operational Phase, several functions such as maintenance, performance monitoring etc. are carried out. In this phase, the Device Management System and the Computerized Maintenance Management Systems are treated as extensions to an Asset Management System that monitors the health of IEDs, generates the Asset Condition Report and alerts the concerned plant personnel.  FIG. 4  shows the stages in the Life Cycle of an IED including the Engineering Phase  47 , the Installation Phase  48  and the Operational Phase  49 . The information pertaining to the state of the IED or assets from the various phases is aggregated into what are termed Aspects, which are the building block for Device Integration Aspect Objects. The different Device Integration Aspect Objects are populated with information from the various life cycle phases and do not correspond to information from a single or a set of life cycle phases. Examples of Aspects within this object include the Definition Aspect, the Documentation Aspect, the Diagnostics Aspect and the Configuration Aspect. 
         [0034]      FIG. 5  shows the details maintained in a Device Integration Aspect Object, which is used to aggregate information from various stages in the life cycle of the IED. The Aspects represented in this object include the Field Device/Sensor definition Aspect  50 , the Field Bus/Sensor Network Management Aspect  51 , the Device/Sensor Health Monitoring and Diagnostics Aspect  52  and the Documentation Aspect  53 . 
         [0035]      FIG. 6  shows an Automation Object  54 , also referred to as a Device Integration Aspect Object  55 . The Device Integration Aspect Object aggregates information having to do with the IED, arranged in terms of Aspects. In this figure, special emphasis is placed on the Documentation Aspect. Documentation about an IED may come from various life cycle stages. For example, the engineering phase could include design documentation such as circuit diagrams  58 . The installation phase might benefit from data sheets  57 . The operational phase might use measurement information  59  and maintenance data  56 . Even though this documentation might be present in different formats, the LCMS of the present invention makes provisions for storing these different formats and converting across formats, when necessary. 
         [0036]      FIG. 7  expands on this Documentation Aspect further by presenting the means in which one subset of the LCMS, the Asset Management function maintains documentation  61  and displays it  62  for one particular IED  60 . 
         [0037]    The present invention has the means for creating Device Integration Aspect Objects to represent real world IEDs from several different perspectives, each perspective being defined as a piece of information. A set of functions to create, access, and manipulate the information is also provided. These different perspectives on a real world object are optionally represented by software applications, which are partly provided by the system vendor. An increasing amount of such software applications are provided by device manufacturers or third party companies, who provide add-on-applications like calibration management or CMMS functionalities. It is desirable to be able to integrate such software without changing the way these applications work internally, whereby it is not reasonable to require that all different applications are aware of each other. 
         [0038]    Examples of device specific components and functions are:
       installation/commissioning of device specific Device Type Manager   Configuration, commissioning and diagnosis   Access to device specific engineering documentation   Connectivity to Asset Monitoring and Asset Management System   Connectivity to Device Management System   Connectivity to Remote Computerized Maintenance Management system.       
 
         [0045]    The LCMS uses the information aggregated in Device Integration Aspect Objects along with information obtained from local Asset Monitors located in the physical process plants, to perform Asset Optimization for IEDs. Since the Device Integration Aspect Objects contain several pieces of relevant information such as engineering documentation, maintenance data, data sheets pertaining to the individual devices etc., the LCMS is able to perform holistic management and optimization, to enhance the life of the IEDs deployed in the field. For example, if an IED encounters a problem, this is reported to the LCMS by the Asset Monitor in the plant. The LCMS goes on to look up the pertinent design documentation that has an answer to the problem. Further, the LCMS might send this error condition to a remote device-vendor, who can send the solution back to the LCMS. This way, the life of the asset is enhanced since a multitude of information and diagnostic support is made available to correct whatever operational challenges the IED/asset may face in it&#39;s lifetime. 
         [0046]      FIG. 3  shows a modular overview of the various components in a Life Cycle Management System. Utilizing data  300  stored in Device Integration Aspect Objects  301 , and information from various asset or device monitors  302  in one or several physical plants  303 ,  304 ,  305 ,  306 ,  307 , each having their own individual configurations, Operating System platforms and maintenance software, the LCMS  25 , performs Asset Management and optimizes the life of the assets in a process plant. It further provides a location-independent design to provide such control and management/optimization functionality by means of connectivity applications, which are used as conduits to communicate information, over such distributed network configurations such as the Internet. Such communication can occur between the customer, whose physical process plants  303 ,  304 ,  305 ,  306 ,  307 , the LCMS of the present invention is controlling. This multitude of process plants indicates the LCMS using a clustered and scalable strategy and demonstrates its use and applicability in a large processing complex. Subsequently, when necessary, connectivity applications  308 , 309  can be used to communicate error information with device vendors or to communicate with any of other CMMS systems or Web Library Servers, which provide updates for various network protocols etc. Further, the LCMS is able to communicate with device vendors, by means of connectivity applications  310 ,  311 , in order to facilitate location-independent debugging or error diagnostics. The LCMS employs one or a plurality of servers  312 , 313 , 314  to carry out Asset Management along with a data store or a plurality of data stores  315 ,  316 , 317 . The data store could optionally use a Redundant Array of Independent Disks, for better availability. The information that is communicated between the different modules is secured by known authentication means. Optionally, the information is accessible by authenticated parties with the use of the Simple Object Access Protocol, or any other markup language  310 ,  311 . 
         [0047]    A two way communication has to occur between the process plant ( 303 - 307  in  FIG. 3) and 38  in  FIG. 2 ) and the control system engineering environment, placed within the LCMS. The communication provides means for the exchangeability of process data, like limits, alarm values or units, between the IEDs and Control module logic and function block structures, within the LCMS, confirming to, IEC-61149, IEC61131-3 and IEC 61804-2.  FIG. 9  shows the bi-directional data exchange between the process engineering environment (PEE)  90  and the control system engineering environment (CSEE)  91  residing within the LCMS. From this exchange we see that the system is configured or initialized  92  with the creation of Device Integration Aspect Objects through an exchange of information between the PEE and the CSEE. Furthermore, the health of the IED is communicated from the control system to the process engineering environment  93 . The LCMS has means to enable this exchange while making provisions for various document formats. 
         [0048]    The IED information is communicated through the Asset Monitor Reports  100 , shown in  FIG. 10 . They contain a plurality of information such as the severity of the condition  102 , the condition itself  103 , the sub-condition  104 , the description of the condition  105 , the timestamp associated with the condition  106  and the quality status  107 . 
         [0049]      FIG. 11  shows the Asset Monitor status reports. The HART generic device Asset Monitor  113  in this case was found to have a good status  115 , have its details about the last execution  116 , and the last time it was started  117 , with the execution statistics  118 , the execution interval  119  and the asset parameters  120 , being shown in the Asset Monitor Status  121 . Every device has only the set of information relevant to it being shown. For example, the Asset Monitor for the ABB Generic HART Device  121 , has only a status field  122 , a Logic field  123 , an execution statistics field  124  and a startup configuration field  125 . 
         [0050]      FIG. 12  shows the Asset Condition Report generated by the LCMS. The asset&#39;s condition details  126 , are communicated by means of detailing the exact condition or sub-condition  127 , a time-stamp recording when the condition took place  128 , the severity of the condition  129 , a description of the condition  130 , the possible cause of the condition  131 , the suggested action  132 , and a log of the corrective action taken  133 . 
         [0051]      FIG. 10-FIG .  12  also demonstrate the homogeneous visual handling and navigation means for accessing Device Integration Aspect Objects and their aspects in Plant/Functional/Location Structures, within the LCMS. 
         [0052]    The LCMS generates an Asset Condition Report and advises the vendor standard predictive maintenance service actions, extending the on-stream availability of IED. Such information can be send via the Internet to any web client or to customer devices such as mobile phones, e-mail accounts and pagers. Further, the LCMS provides connectivity to the third party systems for Device Management and Computerized Maintenance Management Systems. 
         [0053]    In current practice, device vendors provide several remote services and a multitude of web library servers (for different bus protocols such as PNO, ProfiBus, FIART etc.), also enabled by the Internet. The design paradigm is rapidly evolving towards increasing the role of the Internet in basic connectivity of devices and other operations on devices. The LCMS of the present invention takes this design paradigm into consideration and makes provisions for it. 
         [0054]      FIG. 13  shows the integration of the Internet in the process control systems. DTMs are popularly made available by vendors online and device specific DTMs can be downloaded  136  when the customer wants to perform device management  135 . 
         [0055]    The LCMS of the present invention ensures that only the libraries that have passed the check for version compatibility are imported. As the import of objects from the library for the installation/commissioning and application integration functionalities can be rejected, for example, due to version incompatibility, unknown origin, invalid or outdated certifications, etc customers do not have the risk of getting stuck midway in the installation/commissioning process or having face problems in restoring the status-ante. However, a device and its according software cannot be seen as a single entity. Hence, the LCMS has a much wider focus and includes version checks for the operating system or for control system applications like the Control Function Designer, which is used to graphically build the control logic. Hereby the LCMS also considers the customer&#39;s inputs, for example whether the installation/commissioning needs to be conform to IEC 61131-3 or IEC-61804-2 standards and assigns the according documentation. The advantage for the customer is that the system is ready for use, directly after the installation/commissioning and without any further regression tests. This methodology reduces the down time incurred for updates significantly. 
         [0056]      FIG. 8  shows another feature of the LCMS, which involves version checking the overall system  71 , before downloading/upgrading or updating the system in any way. Updates can be made available for a plurality of IEDs or networks  70  and means exist to log the results of the version checking  73  and controlling what is finally installed or rejected  72 . 
         [0057]    The LCMS of the present invention seeks to provide control and optimization in a location-independent fashion, making provisions for such distributed environments as enabled by the Internet. 
         [0058]    Plant operators have available to them a variety of desktop tools, hand-held devices and commercially available Personal Data Assistants (PDAs) to enable them to receive and analyze information pertaining to the IEDs in the plant. The LCMS of the present invention is capable of sending information, having to do with the life cycle of any IED within the plant, to a plant operator, via the Internet. The information is communicated by means of a connectivity application. This connectivity application is provided by the LCMS to ensure at any time that the local applications are in sync with the core system. However, the asset conditions can be checked locally via any standard web browser or customer device as described above. 
         [0059]    The benefit of this approach is that the customer can observe and maintain DDEs locally without the need of a full-blown Control or Asset Optimization or Life Cycle Management system that is physically co-located with the process plant. That means the customer has the full asset management functionality as described above without the initial investment for a local control system and without the ongoing maintenance costs for system updates or version management as described in the first part of the invention disclosure. 
         [0060]    Another advantage of this architecture is that it allows involvement of the device vendor during error diagnosis without the requirement of being on site. Therefore, the vendor simply downloads the connectivity application and can simulate any error condition at another site, to reproduce problems on customer site and will get the according response from the Asset Management Server. This implies that device vendors will have very lean and cost efficient approach for customer specific maintenance. Device vendors can connect to the information made available by the LCMS in order to provide diagnostic support, without being physically present at the plant site. 
         [0061]    The vendor&#39;s diagnostic sub-system  140 , shown in  FIG. 14  just downloads the connectivity application  141  over the Internet  143  and can simulate any error condition at his lab  142  to reproduce problems on customer site and will get the according response from the LCMS  25 . That means that device vendors will have very lean and cost efficient approach for customer specific maintenance.

Technology Classification (CPC): 6