DETAILED DESCRIPTION OF THE INVENTION

[0014] Referring now to FIG. 1 , there is illustrated a block diagram that shows a system, in accordance with a disclosed embodiment. An error controller 10 is connected to one or more machines or machine elements 12 (hereafter referred to simply as machine or machines) in an automation system. Signals from the machine 12 serve as input signals to one or more inputs 14 of the error controller 10 . Internal logic to the error controller 10 uses the inputs to identify possible error conditions. As discussed in greater detail hereinbelow, the error conditions are transmitted to a central controller 16 from error controller outputs 18 of the error controller 10 . The system of FIG. 1 also includes a display monitor 20 which may be used for error analysis and is used in the configuration of the error controller 10 . In another embodiment, the display 20 may be used purely for configuration purposes. In such an embodiment the error analysis is handled from the central controller that will have its central controller display 17 . Configuration of the error controller 10 is achieved through the use of an external controller such as a PC 22 running suitable application software such as Win-SIMOCODE.

[0015] The implementation of an error control system in a production plant or other automation system involves identifying the various machines 12 in the automation system. A separate error controller 10 can be associated with each such machine 12 . Alternatively, one or more error controllers 10 may serve a number of machines 12 . Parameter values are identified for each machine 12 . For example, a conveyor belt motor may have an overload parameter, a thermal overheating parameter, a current input oversupply parameter. Thus the parameters for a machine 12 correspond to the various error conditions associated with the machine 12 that could conceivable arise. Using the PC 22 , the error controller 10 is configured with these parameters. In one embodiment, the controller 10 includes an RS-232 interface to configure it for the particular machine element. The parameters are ascribed, in much the same way as is done for a SIMOCODE®-DP controller, by means of Win-SIMOCODE-DP application software running on the PC 22 . In one embodiment, the output 18 of the error controller 10 is suitably communicated utilizing a PROFIBUS®-DP protocol for communicating signals between the error controller 10 and the central controller 16 .

[0016] In order to ensure that application-specific conditions are taken into account, the invention further requires during the project phase, that plant documentation be analyzed to identify all external conditions that impact the parameters associated with a machine 12 . Thus, each error condition or fault condition is tracked down to its root cause. Error messages are then devised and assigned to each error condition. In this way, the various error conditions associated with a machine element 12 are associated with error messages that are understandable by a user and that clearly define the root cause of a fault. Thus associations of the machine 12 , error conditions, and error messages are contained in a parameter data file.

[0017] Referring now to FIG. 2 , there is illustrated the parameters or error conditions and associated error messages as stored in the form of a data table in a database. FIG. 2 shows a sample database structure having a machine type in a first column 23 , a list of error conditions that correspond to the machine type in a second column 24 , and a third column 26 providing the corresponding error message that is assigned to the error condition o that particular machine. The database serves as a look-up table to either automatically provide detailed error messages to a user or to form the basis of a help feature that is accessible by a user when an error condition arises.

[0018] It will be appreciated that the database of parameter data files relating the machine 12 , and error conditions to the error messages may be stored internal to the error controller 10 in a memory 11 or external in a storage unit 13 . Note that memory 11 and the storage unit 13 are suitable for accommodating the database, and where necessary, are non-volatile such that the database information is retained under loss-of-power or power fluctuation conditions. Instead, the database may be stored in a separate memory device, with the error controller 10 simply supplying the error condition which is then used to extract the corresponding error message from the separately stored database. Further, the parameter data file database may be stored local to the central controller 16 in an internal storage 19 comprising, for example, a non-volatile memory. Additionally, the database of files may be stored external to the central controller in a storage until 15 for access thereto. Where the parameter database (in either or both storage 19 or storage 15 ) is local to the central controller 16 , the error controller 10 can then provide only the error condition to the central controller 16 such the central controller accesses the parameter database to obtain the corresponding error message. Such an implementation is useful for legacy error controller systems that are incapable of providing error condition/message resolution from a database.

[0019] Referring now to FIG. 3 , there is illustrated a flow chart of the process for configuring and implementing the system, in accordance with a disclosed embodiment. Flow begins at a function block 30 where the system is segmented into functional blocks to which error conditions and error messages will be assigned. Error conditions are then defined for each functional block, as indicated in flow to a function block 32 . One or more causes for each error condition are then defined, as indicated in flow to a function block 34 . Flow is then to a function block 36 where error messages that are displayed or presented to a user, are developed. The error messages are designed to be informative to the user in that the user does not need to reference a conversion chart or similar reference to understand the nature and source of the error condition.

[0020] Once all of the associations for the machine, error conditions, and error messages have been defined and developed, flow is to a function block 38 where the associations are stored in a database that is accessible and readable by the error controller 10 . As mentioned hereinabove, the associations of the machine, error conditions, and error messages are developed on the PC 22 , and when complete, communicated to the database associated with the error controller for future access by the error controller 10 .

[0021] Once the system is brought on-line, as indicated in a function block 40 , any fault occurring in the machine 12 is input to the error controller 10 wherein the database is accessed. The machine 12 outputs a machine signal to the error controller 10 that is interpretable by the error controller 10 as coming from that particular machine 12 . Further, the machine signal includes an error condition that when compared against the database, returns a corresponding error message extracted from the database that is presented to the technician or operator, as indicated in a function block 42 . The process of displaying the error message is accomplished by the error controller 10 to the display 20 . Alternatively, the central controller 16 receives the error message from the error controller 10 via a communication bus compatible with output 18 such that the central controller 16 presents the error messages to a user via the central controller display 17 . Note that the error message may optionally be displayed under control of the error controller to the central controller display 17 . The user or technician can then more readily ascertain the cause and source of the fault condition, and expedite a safe shutdown and/or repair of the system, if such an action is required.

[0022] It is appreciated that display of the error messages can be accomplished over a conventional packet-switched network such that the central controller 16 communicates the error messages over the network to a remote display of the technician at a location remote from the site of the system. For example, the network can be a global communication network, e.g., the Internet, such that the technician monitors the system from a control room located geographically remote from the system or system being monitored.

[0023] Alternatively, the error messages can be presented audibly instead of, or in conjunction with, display thereof utilizing conventional signal conversion technology. The technician can then hear the error message when announced, and react accordingly.

[0024] Alternatively still, the error message can be converted for communication to the technician via a wireless device, e.g., a pager, such that the technician can view text of the error message from the wireless device at remote location.

[0025] The present invention has been described with reference to a particular sample system, and a certain nomenclature was adopted to define the various components, signals and conditions. It will be appreciated that different embodiments could be created without departing from the essence of the invention as claimed in the attached claims.