Remote terminal unit (RTU) with universal input/output (UIO) and related method

• US 10,248,601 B2
• Filed: 03/27/2014
• Issued: 04/02/2019
• Est. Priority Date: 03/27/2014
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: McLaughlin, Paul F., Eisner, David A., Urso, Jason T.
• Primary Examiner(s): Lee, Chun Kuan
• Application Number:
  US14/228,142
• Publication Number:
  US 20150278144A1
• Time in Patent Office: 1,832 Days
• Field of Search: 710104
• CPC Class Codes: G06F 13/4027 using bus bridges G06F13/4022 takes precedence
• CPC Class Codes: G06F 9/44505 Configuring for program initiating, e.g. using registry, configuration files
• CPC Class Codes: Y02D 10/00 Energy efficient computing, e.g. low power processors, power management or thermal management

Abstract

A system includes at least one industrial control and automation field device and a remote terminal unit (RTU). The RTU includes input/output (I/O) terminals configured to be coupled to the field devices. The RTU also includes one or more I/O modules having one or more reconfigurable I/O channels configured to be coupled to the I/O terminals. Each reconfigurable I/O channel is configurable as an analog input, an analog input supporting digital communication, an analog output, an analog output supporting digital communication, a digital input, a digital output, and a pulse accumulator input. The RTU further includes at least one processing device configured to control a configuration of each of the one or more reconfigurable I/O channels.

Claims

1. An apparatus comprising:

a remote terminal unit (RTU) comprising;

input/output (I/O) terminals configured to be coupled to at least one industrial control and automation field device;

one or more first I/O modules comprising one or more first reconfigurable I/O channels, each first reconfigurable I/O channel configured to be coupled to a pair of the I/O terminals, each first reconfigurable I/O channel configurable as an analog input, an analog input supporting digital communication, an analog output, an analog output supporting digital communication, a digital input, a digital output, and a pulse accumulator input for communication through the pair of I/O terminals;

each of the one or more first reconfigurable I/O channel comprises;

a digital logic block configured to control operating states for devices connected to the pair of I/O terminals using logic signals;

an analog common resource block configured to convert digital and analog signals between the digital logic block and the pair of I/O terminals;

a multiplexer block configured to receive a current signal from the analog common resource block and output a voltage signal to the analog common resource block; and

an output circuit block that comprises a plurality of switches and is configured to;

connect the current signal from the analog common resource block to a first I/O terminal of the pair of I/O terminals; and

connect a second I/O terminal of the pair of I/O terminals to an input of the multiplexer block;

a first expansion board coupled to the one or more first I/O modules;

a second expansion board configured to be coupled to one or more second I/O modules comprising one or more second reconfigurable I/O channels, wherein the second expansion board is connected to the first expansion board;

first and second electric paths formed through the first expansion board and the second expansion board, wherein the first and second electric paths meet at a loop after a final expansion board to indicate a lack of any additional I/O modules or additional expansion boards;

at least one processing device configured to control a configuration of each of the one or more first reconfigurable I/O channels and each of the one or more second reconfigurable I/O channels and to control the one or more second reconfigurable I/O channels through the one or more first I/O modules;

a first circuit board coupled to the I/O terminals and the first expansion board, wherein the first circuit board is further coupled to one or more serial interfaces, one or more uplink/downlink ports, and one or more transformers coupled to the first expansion board;

a second circuit board coupled to the at least one processing device, wherein the second circuit board is further coupled to one or more transceivers configured to communicate with the first circuit board; and

a third circuit board coupled to the one or more first I/O modules, wherein the third circuit board is further coupled to a power converter, the power converter configured to convert power received from the second circuit board;

wherein the first circuit board is coupled to the second and third circuit boards.

2. The apparatus of claim 1, wherein the RTU further comprises:

a first controller comprising the at least one processing device.

3. The apparatus of claim 2, wherein:

the one or more first reconfigurable I/O channels in the one or more first I/O modules are coupled directly to the first controller; and

the one or more second reconfigurable I/O channels in the one or more second I/O modules are coupled indirectly to the first controller via the first expansion board.

4. The apparatus of claim 2, wherein the first and second electrical paths extend from the first controller through the one or more first I/O modules and the one or more second I/O modules.

5. The apparatus of claim 2, wherein:

the RTU further comprises a second controller; and

the first controller is configured to operate as a primary controller and the second controller is configured to operate as a secondary controller.

6. The apparatus of claim 1, wherein the plurality of switches comprises:

a first switch coupled between a sense resistor and the first I/O terminal;

a second switch coupled between the second I/O terminal and an analog ground;

a third switch coupled between a negative side of a second resistor and the analog ground; and

a fourth switch coupled between the first I/O terminal and the negative side of the second resistor.

7. The apparatus of claim 1, wherein the RTU further comprises:

one or more fixed I/O channels, each fixed I/O channel comprising one of;

a non-reconfigurable input channel and a non-reconfigurable output channel.

8. A system comprising:

at least one industrial control and automation field device; and

a remote terminal unit (RTU) comprising;

input/output (I/O) terminals configured to be coupled to the at least one field device;

one or more first I/O modules comprising one or more first reconfigurable I/O channels, each first reconfigurable I/O channel configured to be coupled to a pair of the I/O terminals, each first reconfigurable I/O channel configurable as an analog input, an analog input supporting digital communication, an analog output, an analog output supporting digital communication, a digital input, a digital output, and a pulse accumulator input for communication through the pair of I/O terminals;

each of the one or more first reconfigurable I/O channel comprises;

a digital logic block configured to control operating states for devices connected to the pair of I/O terminals using logic signals;

an analog common resource block configured to convert digital and analog signals between the digital logic block and the pair of I/O terminals;

a multiplexer block configured to receive a current signal from the analog common resource block and output a voltage signal to the analog common resource block; and

an output circuit block that comprises a plurality of switches and is configured to;

connect the current signal from the analog common resource block to a first I/O terminal of the pair of I/O terminals; and

connect a second I/O terminal of the pair of I/O terminals to an input of the multiplexer block;

a first expansion board coupled to the one or more first I/O modules;

a second expansion board configured to be coupled to one or more second I/O modules comprising one or more second reconfigurable I/O channels, wherein the second expansion board is connected to the first expansion board;

first and second electric paths formed through the first expansion board and the second expansion board, wherein the first and second electric paths meet at a loop after a final expansion board to indicate a lack of any additional I/O modules or additional expansion boards;

at least one processing device configured to control a configuration of each of the one or more first reconfigurable I/O channels and each of the one or more second reconfigurable I/O channels and to control the one or more second reconfigurable I/O channels through the one or more first I/O modules;

a first circuit board coupled to the I/O terminals and the first expansion board, wherein the first circuit board is further coupled to one or more serial interfaces, one or more uplink/downlink ports, and one or more transformers coupled to the first expansion board;

a second circuit board coupled to the at least one processing device, wherein the second circuit board is further coupled to one or more transceivers configured to communicate with the first circuit board; and

a third circuit board coupled to the one or more first I/O modules, wherein the third circuit board is further coupled to a power converter, the power converter configured to convert power received from the second circuit board;

wherein the first circuit board is coupled to the second and third circuit boards.

9. The system of claim 8, wherein:

the RTU further comprises a first controller comprising the at least one processing device;

the one or more first reconfigurable I/O channels in the one or more first I/O modules are coupled directly to the first controller; and

the one or more second reconfigurable I/O channels in the one or more second I/O modules are coupled indirectly to the first controller via the first expansion board.

10. The system of claim 9, wherein:

the RTU further comprises a second controller; and

the first controller is configured to operate as a primary controller and the second controller is configured to operate as a secondary controller.

11. The system of claim 9, wherein the first and second electrical paths extend from the first controller through the one or more first I/O modules and the one or more second I/O modules.

12. The system of claim 8, wherein the plurality of switches comprises:

a first switch coupled between a sense resistor and the first I/O terminal;

a second switch coupled between the second I/O terminal and an analog ground;

a third switch coupled between a negative side of a second resistor and the analog ground; and

a fourth switch coupled between the first I/O terminal and the negative side of the second resistor.

13. The system of claim 8, wherein the RTU further comprises:

a controller that is physically separated from the one or more first I/O modules; and

one or more communication paths configured to communicatively couple the controller and the one or more first I/O modules; and

wherein the controller and the one or more first I/O modules are configured to be powered by different power supplies.

14. The system of claim 8, further comprising:

an asset manager configured to configure and manage operations of the at least one field device via the RTU.

15. The system of claim 8, wherein the RTU further comprises:

one or more fixed I/O channels, each fixed I/O channel comprising one of;

a non-reconfigurable input channel and a non-reconfigurable output channel.

16. A method comprising:

coupling at least one industrial control and automation field device to input/output (I/O) terminals of a remote terminal unit (RTU);

using at least one processing device, configuring (i) one or more first reconfigurable I/O channels that are coupled to the I/O terminals in one or more first I/O modules that are coupled to a first expansion board of the RTU and (ii) one or more second reconfigurable I/O channels in one or more second I/O modules that are coupled to a second expansion board of the RTU, wherein the at least one processing device controls the one or more second reconfigurable I/O channels through the one or more first I/O modules;

each of the one or more first reconfigurable I/O channel comprises;

a digital logic block configured to control operating states for devices connected to the pair of I/O terminals using logic signals;

an analog common resource block configured to convert digital and analog signals between the digital logic block and the pair of I/O terminals;

a multiplexer block configured to receive a current signal from the analog common resource block and output a voltage signal to the analog common resource block; and

an output circuit block that comprises a plurality of switches and is configured to;

connect the current signal from the analog common resource block to a first I/O terminal of the pair of I/O terminals; and

connect a second I/O terminal of the pair of I/O terminals to an input of the multiplexer block;

forming first and second electric paths through the first expansion board and the second expansion board, wherein the first and second electric paths meet at a loop after a final expansion board to indicate a lack of any additional I/O modules or additional expansion boards;

coupling a first circuit board to the I/O terminals and the first expansion board, wherein the first circuit board is further coupled to one or more serial interfaces, one or more uplink/downlink ports, and one or more transformers coupled to the first expansion board;

coupling a second circuit board to the at least one processing device, wherein the second circuit board is further coupled to one or more transceivers configured to communicate with the first circuit board;

coupling a third circuit board to the one or more first I/O modules, wherein the third circuit board is further coupled to a power converter, the power converter configured to convert power received from the second circuit board;

wherein each first and second reconfigurable I/O channel is configurable as an analog input, an analog input supporting digital communication, an analog output, an analog output supporting digital communication, a digital input, a digital output, and a pulse accumulator input for communication through a pair of the I/O terminals; and

wherein the first circuit board is coupled to the second and third circuit boards.

17. The method of claim 16, further comprising:

coupling a first controller and a second controller to the one or more first I/O modules; and

operating the first controller and the second controller as a redundant pair.

18. The method of claim 16, further comprising:

after configuring the one or more first reconfigurable I/O channels, reconfiguring at least one of the one or more first reconfigurable I/O channels to be of a different type of I/O channel.