Apparatus and method for on-process migration of industrial control and automation system across disparate network types

• US 10,148,485 B2
• Filed: 09/03/2014
• Issued: 12/04/2018
• Est. Priority Date: 09/03/2014
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Prall, John M., McLaughlin, Paul F., Novak, Michael E., Gustin, Jay W.
• Primary Examiner(s): Vu, Tuan
• Application Number:
  US14/476,355
• Publication Number:
  US 20160062350A1
• Time in Patent Office: 1,553 Days
• CPC Class Codes: G05B 19/41855 by local area network [LAN], network structure
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/31115 Network controller
• CPC Class Codes: H04L 12/462 LAN interconnection over a bridge based backbone
• CPC Class Codes: H04L 41/042 comprising distributed management centres cooperatively managing the network
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An apparatus includes a first network controller configured to communicate over a higher-level industrial process control network, a second network controller configured to communicate over a first lower-level industrial process control network, and a third network controller configured to communicate over a second lower-level industrial process control network. The first network controller is configured to provide first data messages from the higher-level control network to the second and third network controllers for transmission over the lower-level control networks. The second and third network controllers are configured to provide second data messages from the lower-level control networks to the first network controller for transmission over the higher-level control network. Each of the second and third network controllers is configured to provide third data messages from one of the lower-level control networks to another of the second and third network controllers for transmission over another of the lower-level control networks.

Claims

1. An apparatus comprising:

a first network controller configured to communicate over a higher-level industrial process control network;

a second network controller configured to communicate over a legacy lower-level industrial process control network using a legacy protocol, the second network controller comprising a token bus controller configured to communicate over a token bus of the legacy lower-level industrial process control network;

a third network controller configured to communicate over an enhanced lower-level industrial process control network using an enhanced protocol, the third network controller comprising a token bus controller emulator; and

a housing configured to encase the first, second, and third network controllers;

wherein the first network controller is configured to provide first data messages from the higher-level industrial process control network to the second and third network controllers for transmission over the lower-level industrial process control networks;

wherein the second and third network controllers are configured to provide second data messages from the lower-level industrial process control networks to the first network controller for transmission over the higher-level industrial process control network;

wherein each of the second and third network controllers is configured to provide third data messages from one of the lower-level industrial process control networks to another of the second and third network controllers for transmission over another of the lower-level industrial process control networks; and

wherein at least one of the second and third network controllers is configured to translate the third data messages between the legacy protocol and the enhanced protocol.

2. The apparatus of claim 1, further comprising:

a first physical interface coupled to the first network controller and configured to be coupled to the higher-level industrial process control network;

a second physical interface coupled to the second network controller and configured to be coupled to the legacy lower-level industrial process control network; and

a third physical interface coupled to the third network controller and configured to be coupled to the enhanced lower-level industrial process control network.

3. The apparatus of claim 2, wherein:

the first physical interface is configured to be coupled to a redundant coaxial control network;

the second physical interface is configured to be coupled to a coaxial or redundant coaxial control network; and

the third physical interface is configured to be coupled to an Ethernet network or a redundant Ethernet network.

4. The apparatus of claim 1, further comprising:

a first shared memory block configured to buffer the first and second data messages, the first and second network controllers configured to access the first shared memory block.

5. The apparatus of claim 4, further comprising:

a second shared memory block configured to buffer at least the third data messages, the second and third network controllers configured to access the second shared memory block.

6. The apparatus of claim 1, wherein:

the second network controller comprises logical link control (LLC) firmware configured to route a first portion of the second data messages to the first network controller and to route a first portion of the third data messages to the third network controller; and

the third network controller comprises LLC firmware configured to route a second portion of the second data messages to the first network controller and to route a second portion of the third data messages to the second network controller.

7. The apparatus of claim 1, wherein the apparatus is configured to provide control devices on the higher-level industrial process control network with concurrent access to control devices on the legacy and enhanced lower-level industrial process control networks.

8. The apparatus of claim 1, wherein the first network controller comprises a network interface module (NIM) personality configured to provide a gateway functionality.

9. A method implemented with controllers having processor capabilities and circuitry to process instructions and network inter-communicated data, the method comprising:

receiving first data messages from a higher-level industrial process control network at a first network controller of an interface device;

providing, by the first network controller, the first data messages to second and third network controllers of the interface device for transmission over legacy and enhanced lower-level industrial process control networks, respectively, wherein the second network controller comprises a token bus controller configured to communicate over a token bus of the legacy lower-level industrial process control network, wherein the third network controller comprises a token bus controller emulator;

receiving second data messages from the lower-level industrial process control networks at the second and third network controllers;

providing, by the second and third network controllers, the second data messages to the first network controller for transmission over the higher-level industrial process control network;

receiving, at each of the second and third network controllers, third data messages from one of the lower-level industrial process control networks;

translating, by the second and third network controllers, the third data messages between a legacy protocol associated with the legacy lower-level industrial process control network and an enhanced protocol associated with the enhanced lower-level industrial process control network; and

providing, from each of the second and third network controllers to another of the second and third network controllers, the translated third data messages for transmission over another of the lower-level industrial process control networks;

wherein the first, second, and third network controllers are disposed in a same housing of the interface device.

10. The method of claim 9, wherein the interface device transports the third data messages from the second network controller to the third network controller and from the third network controller to the second network controller.

11. The method of claim 9, further comprising:

coupling a first physical interface of the interface device to the higher-level industrial process control network, the first physical interface coupled to the first network controller;

coupling a second physical interface of the interface device to the legacy lower-level industrial process control network, the second physical interface coupled to the second network controller; and

coupling a third physical interface of the interface device to the enhanced lower-level industrial process control network, the third physical interface coupled to the third network controller.

12. The method of claim 11, wherein:

the first physical interface is coupled to a redundant coaxial control network;

the second physical interface is coupled to a coaxial or redundant coaxial control network; and

the third physical interface is coupled to an Ethernet network or a redundant Ethernet network.

13. The method of claim 9, further comprising:

using a first shared memory block to buffer the first and second data messages, the first and second network controllers configured to access the first shared memory block.

14. The method of claim 13, further comprising:

using a second shared memory block to buffer at least the third data messages, the second and third network controllers configured to access the second shared memory block.

15. The method of claim 9, wherein:

the second network controller comprises logical link control (LLC) firmware that routes a first portion of the second data messages to the first network controller and routes a first portion of the third data messages to the third network controller; and

the third network controller comprises LLC firmware that routes a second portion of the second data messages to the first network controller and routes a second portion of the third data messages to the second network controller.

16. The method of claim 9, further comprising:

providing control devices on the higher-level industrial process control network with concurrent access to control devices on the legacy and enhanced lower-level industrial process control networks using the interface device.

17. A system comprising:

first, second, and third network controllers configured to communicate over higher-level, legacy lower-level, and enhanced lower-level industrial process control networks, respectively;

wherein the second network controller comprises a token bus controller configured to communicate over a token bus of the legacy lower-level industrial process control network, wherein the third network controller comprises a token bus controller emulator;

at least one processing device configured to provide a gateway function to allow data messages to be transported between (i) the higher-level industrial process control network and (ii) the lower-level industrial process control networks, wherein the second and third network controllers are configured to provide a bridge function to allow data messages to be transported between (i) the legacy lower-level industrial process control network and (ii) the enhanced lower-level industrial process control network;

a bus configured to transport the data messages between the network controllers; and

a housing configured to encase the network controllers, the at least one processing device, and the bus,

wherein the first network controller is configured to provide data messages from the high-level industrial process control network to the second and third network controllers for transmission over the lower-level industrial process control networks, and to receive from lower-level industrial process control networks data messages provided by the second and third network controllers;

wherein at least one of the second and third network controllers is configured to receive data messages from lower-level control networks to another of the second and third network controllers for transmission over other lower-level industrial control networks; and

translate at least some of the data messages between a legacy protocol associated with the legacy lower-level industrial process control network and an enhanced protocol associated with the enhanced lower-level industrial process control network.

18. The system of claim 17, wherein:

the second network controller further comprises;

logical link control (LLC) firmware configured to route a first portion of the data messages to the first and third network controllers; and

the third network controller further comprises;

LLC firmware configured to route a second portion of the data messages to the first and second network controllers.

19. The system of claim 17, further comprising:

a first physical interface coupled to the first network controller and configured to be coupled to the higher-level industrial process control network;

a second physical interface coupled to the second network controller and configured to be coupled to the legacy lower-level industrial process control network; and

a third physical interface coupled to the third network controller and configured to be coupled to the enhanced lower-level industrial process control network.

20. The system of claim 17, wherein the first network controller comprises a network interface module (NIM) personality configured to provide a gateway functionality.