Method and automation system for replacing an existing control device in an automation system with a new control device and automation system designed for this purpose

• US 9,383,731 B2
• Filed: 03/10/2011
• Issued: 07/05/2016
• Est. Priority Date: 03/10/2010
• Status: Expired due to Fees

• Current Assignee: Siemens AG
• Original Assignee: Siemens AG
• Inventors: Polzer, Kurt
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): Norton, Jennifer L
• Application Number:
  US13/583,891
• Publication Number:
  US 20130218306A1
• Time in Patent Office: 1,944 Days
• Field of Search: 700/19, 700/21, 700/79, 340/3.1, 340/6.1, 714/4.2, 714/25, 714/37, 714/E11.08, 714/E11.081
• US Class Current: 1/1
• CPC Class Codes: G05B 11/01 electric
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 19/058 Safety, monitoring
• CPC Class Codes: G05B 19/41845 characterised by system universality, reconfigurability, modularity
• CPC Class Codes: G05B 2219/25471 Replace existing control system with new different system in real time
• CPC Class Codes: G05B 2219/31251 Redundant access, wireless and hardware access to fielddevices
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

In an automation system, a control device processes measured values received from automation components and generates control values for the, or for individual, automation components and/or other automation components. In order to shorten down times when replacing an existing control device, the new control device is tested during operation of the existing control device, for which purpose the measured values and control values are wirelessly transmitted to the new control device and the control values generated by the device are compared to the control values generated by the existing control device. After the test, the control values generated by the new control device are output to the automation components instead of the control values generated by the existing control device.

Claims

1. A method for replacing an existing control device in an automation system by a new control device, the method comprising the steps of:

receiving, by the existing control device, measured values from automation components, processing the received measured values, generating control values for at least one of said automation components and other automation components and outputting control values from the existing control device to the at least one automation component, at least some of the automation components being connected to the existing control device over wired communication paths;

testing the new control device by (i) transmitting the measured values to be received by the existing control device and the control values generated by and output from the existing control device upon receipt of the received measured value wirelessly to the new control device based on a switch position of a changeover unit, (ii) generating, by a regulation algorithm of the new control device, control values and supplying the generated control values through a further changeover unit to a comparison unit and (iii) comparing, via the comparison unit, control values upon receipt of the transmitted measured values generated by the new control device with the control values generated by and output from the existing control device;

outputting, after successfully testing the new control device, the control values generated by the new control device to the automation components instead of the control values generated by the existing control device; and

disconnecting the wired communication paths from the existing control device after the testing and connecting the wired communication paths to the new control device.

2. The method as claimed in claim 1, wherein the automation components include radio adapters for wireless transmission of at least one of the measured values and control values to the new control device.

3. An automation system with an existing control to be replaced by a new control device, the automation system comprising,

the existing and new control devices being configured to receive measured values from automation components of the automation system, process the received measured values and generate control values for said automation components and other automation components of the automation system;

wherein the automation components each comprise a transmission device for wirelessly transmitting the measured values and control values received from the existing control device to the new control device;

wherein the new control device comprises a changeover unit for supplying measured values based on a switch position, and a regulation algorithm for generating the control values and supplying the generated control values through a further changeover unit to a comparison unit for comparing control values generated by the new control device upon receipt of the transmitted measured values with the received control values from the automation components; and

the new control device further outputting the control values generated by the new control device to the automation components instead of the control values generated by the existing control device when desired comparison results are generated.

4. The automation system as claimed in claim 3, wherein the transmission device consist of radio adapters detachably mounted on the automation components.