Automated retrofit installation tool for replacement of one or more pre-existing dedicated input/output (I/O) modules and terminal boards with one or more universal I/O modules

• US 10,366,033 B2
• Filed: 09/15/2016
• Issued: 07/30/2019
• Est. Priority Date: 09/15/2016
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Alley, Daniel Milton, Carter, Roy Anthony, Sherman, Joshua
• Primary Examiner(s): Abad, Farley
• Assistant Examiner(s): Yu, Henry W
• Application Number:
  US15/266,447
• Publication Number:
  US 20180074987A1
• Time in Patent Office: 1,048 Days
• Field of Search: 710 2, 710 10- 11, 710 14, 710 16, 710 62- 63, 710100, 710301-302
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/054 Input/output
• CPC Class Codes: G05B 2219/21087 Define sensor type, resistance, thermocouple, thermistor, voltage, current
• CPC Class Codes: G05B 2219/2243 Detect incompatibilites between control devices
• CPC Class Codes: G05B 2219/25061 Configuration stored in central database
• CPC Class Codes: G05B 2219/25074 Check system, change failing element, compare with stored configuration
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/25454 Retrofitting
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/33331 Test, diagnostic of field device for correct device, correct parameters
• CPC Class Codes: G06F 13/382 using universal interface adapter
• CPC Class Codes: G06F 13/385 for adaptation of a particular data processing system to different peripheral devices
• CPC Class Codes: G06F 13/4022 using switching circuits, e.g. switching matrix, connection or expansion network G06F13/4009 takes precedence
• CPC Class Codes: G06F 13/4282 on a serial bus, e.g. I2C bus, SPI bus on daisy chain buses G06F13/4247
• CPC Class Codes: H05K 5/026 having standardized interfaces flash memory cards G06K19/077

Abstract

Described are systems, methods and computer-program product for replacing a prior input/output (I/O) module and terminal board with a universal I/O device by providing software based instructions and configuration settings for the installer. The method includes provisions for new wiring changes or harnesses as well as preset adapters, converting prior device configuration settings from an I/O module, pack, and/or terminal board to new configuration settings for a programmable I/O device, generating a wiring chart for any wiring changes based on the settings, and displaying the information for the installer and/or programmer'"'"'s use. This allows a universal I/O device capable of each channel having different operating modes to replace one or more of a mixture of several types of dedicated I/O modules. The installation documentation and configurations are automatically generated, reducing the chance of errors due to misinterpretation of multiple product documents while allowing the automatic transfer of product settings.

Claims

1. A method for facilitating the replacement of pre-existing dedicated input/output (I/O) modules with universal I/O modules, wherein the method is implemented using a computer system including a processor and a memory, the method comprising:

obtaining information about one or more pre-existing dedicated I/O modules, wherein the information includes a plurality of functions of the one or more pre-existing dedicated I/O modules;

determining one or more functions of the one or more pre-existing dedicated I/O modules that can be performed by one or more universal I/O modules;

determining, prior to installation of the one or more universal I/O modules, any gaps between the plurality of functions of the one or more pre-existing dedicated I/O modules and the one or more functions that can be performed by the one or more universal I/O modules;

providing instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules, wherein the instructions include the gaps between the plurality of functions of the one or more pre-existing dedicated I/O modules and the one or more functions that can be performed by the one or more universal I/O modules; and

generating a wiring diagram showing wiring to the one or more universal I/O modules using existing wiring in the one or more pre-existing dedicated I/O modules and at least one of a new wiring and a new wiring harness.

2. The method of claim 1, wherein the computer system receives the information as information input by use of a keyboard, barcode scanner, or received as image information from an image capture device.

3. The method of claim 1, wherein obtaining information about the one or more pre-existing dedicated I/O modules further comprises performing a database lookup for the information based on receiving, by the computer system, identification information that identifies the one or more pre-existing dedicated I/O modules.

4. The method of claim 1, wherein the one or more pre-existing dedicated I/O modules comprise one or more thermocouple (TC) modules, resistance temperature detector (RTD) modules, analog I/O modules, digital I/O modules, and communication modules.

5. The method of claim 1, wherein determining the one or more functions of the one or more pre-existing dedicated I/O modules that can be performed by the one or more universal I/O modules further comprises determining a number of channels of thermocouple (TC) I/O, resistance temperature detector (RTD) I/O, analog I/O, digital I/O, and communication I/O on the one or more pre-existing dedicated I/O modules that will be replaced by the one or more universal I/O modules.

6. The method of claim 1, wherein providing instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules further comprises preparing a report of spare channels on the one or more universal I/O modules, creating wiring diagrams for wiring in the one or more universal I/O modules, and creating configuration files and software settings for software that interfaces with the one or more universal I/O modules.

7. The method of claim 1, wherein providing instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules further comprises specifying a wiring harness, connectors and wiring instructions for connecting the pre-existing dedicated I/O modules with the one or more universal I/O modules with the wiring harness and one or more connectors.

8. The method of claim 1, further comprising displaying the instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules.

19. The method of claim 1 further comprising:

determining, after providing instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules after installation of the one or more universal I/O modules, whether additional channels and/or additional new universal I/O modules are needed to complete the transition from the pre-existing dedicated I/O modules to the universal I/O modules.

20. The method of claim 1 further comprising:

updating system files on an industrial control system to facilitate data flow between the one or more universal I/O modules to and application code of the industrial control system.

9. A method for facilitating the replacement of pre-existing dedicated input/output (I/O) modules with universal I/O modules, wherein the method is implemented using a computer system including a processor and a memory, the method comprising:

obtaining information about one or more pre-existing dedicated I/O modules, wherein the information includes a plurality of functions of the one or more pre-existing dedicated I/O modules;

determining one or more functions of the one or more pre-existing dedicated I/O modules that can be performed by the one or more universal I/O modules; and

if the plurality of functions of the one or more pre-existing dedicated I/O modules can be performed by the one or more universal I/O modules, then either;

a. preparing a report of spare channels on the one or more universal I/O modules, creating wiring diagrams for wiring in the one or more universal I/O modules, and creating configuration files and software settings for software that interfaces with the one or more universal I/O modules;

or

b. specifying a wiring harness, connectors and wiring instructions for connecting the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules with the wiring harness and one or more connectors;

else

if at least one function of the plurality of functions of the one or more pre-existing dedicated I/O modules cannot be performed by the one or more universal I/O modules, then;

a. determining, prior to installation of the one or more universal I/O modules, any gaps between the plurality of functions of the one or more pre-existing dedicated I/O modules and the one or more functions that can be performed by the one or more universal I/O modules; and

b. preparing a report of spare channels on the one or more universal I/O modules, creating wiring diagrams for wiring in the one or more universal I/O modules, and creating configuration files and software settings for software that interfaces with the one or more universal I/O modules, wherein the report identifies the gaps.

10. The method of claim 9, wherein the computer system receives the information as information input by use of a keyboard, barcode scanner, or received as image information from an image capture device.

11. The method of claim 9, wherein obtaining information about the one or more pre-existing dedicated I/O modules further comprises performing a database lookup for the information based on receiving, by the computer system, identification information that identifies the one or more pre-existing dedicated I/O modules.

12. The method of claim 9, wherein the one or more pre-existing dedicated I/O modules comprise one or more thermocouple (TC) modules, resistance temperature detector (RTD) modules, analog I/O modules, digital I/O modules, and communication modules.

13. The method of claim 9, wherein determining the one or more functions of the one or more pre-existing dedicated I/O modules that can be performed by the one or more universal I/O modules further comprises determining a number of channels of thermocouple (TC) I/O, resistance temperature detector (RTD) I/O, analog I/O, digital I/O, and communication I/O on the one or more pre-existing dedicated I/O modules that will be replaced by the one or more universal I/O modules.

14. The method of claim 9, further comprising displaying instructions for replacement of one or more pre-existing dedicated I/O modules with one or more universal I/O modules.

15. A non-transitory computer-readable medium with computer-executable instructions thereon, the computer executable instructions for performing a method for facilitating the replacement pre-existing dedicated input/output (I/O) modules with universal I/O modules, wherein, when executed by at least one processor in communication with at least one memory, the computer executable instructions cause the at least one processor to:

obtain information about one or more pre-existing dedicated I/O modules, wherein the information includes a plurality of functions of the one or more pre-existing dedicated I/O modules;

determine one or more functions of the one or more pre-existing dedicated I/O modules that can be performed by the one or more universal I/O modules;

determine, prior to installation of the one or more universal I/O modules, any gaps between the plurality of functions of the one or more pre-existing dedicated I/O modules and the one or more functions that can be performed by the one or more universal I/O modules;

provide instructions for replacement of the one or more pre-existing dedicated I/O modules with the one or more universal I/O modules, wherein the instructions include the gaps between the plurality of functions of the one or more pre-existing dedicated I/O modules and the one or more functions that can be performed by the one or more universal I/O modules; and

generate a wiring diagram showing wiring to the one or more universal I/O modules using existing wiring in the one or more pre-existing dedicated I/O modules and at least one of a new wiring and a new wiring harness.

16. The computer-readable medium of claim 15, wherein the computer executable instructions further cause the at least one processor to determine a number of channels of thermocouple (TC) I/O, resistance temperature detector (RTD) I/O, analog I/O, digital I/O, and communication I/O on the one or more pre-existing dedicated I/O modules that will be replaced by the one or more universal I/O modules.

17. The computer-readable medium of claim 15, wherein the computer executable instructions further cause the at least one processor to prepare a report of spare channels on the one or more universal I/O modules, create wiring diagrams for wiring in the one or more universal I/O modules, and create configuration files and software settings for software that interfaces with the one or more universal I/O modules.

18. The computer-readable medium of claim 15, wherein the computer executable instructions further cause the at least one processor to specify a wiring harness, connectors and wiring instructions for connecting the pre-existing dedicated I/O modules with the one or more universal I/O modules with the wiring harness and one or more connectors.