Configurable, connectorized server-augmented control system

• US 10,404,529 B2
• Filed: 04/30/2013
• Issued: 09/03/2019
• Est. Priority Date: 04/30/2012
• Status: Active Grant

• Current Assignee: Xio, Inc. (RIZAP GROUP, Inc.)
• Original Assignee: Xio, Inc. (RIZAP GROUP, Inc.)
• Inventors: Sagues, Paul, Botha, Mauritz
• Primary Examiner(s): Taylor, Nicholas R
• Assistant Examiner(s): Kim, Chong G
• Application Number:
  US13/874,217
• Publication Number:
  US 20130290496A1
• Time in Patent Office: 2,317 Days
• Field of Search: 709220
• CPC Class Codes: G05B 19/054 Input/output
• CPC Class Codes: G05B 2219/24215 Scada supervisory control and data acquisition
• CPC Class Codes: H04L 41/0803 Configuration setting
• CPC Class Codes: H04L 67/125 involving control of end-device applications over a network
• CPC Class Codes: Y04S 40/18 Network protocols supporting networked applications, e.g. including control of end-device applications over a network

Abstract

A configurable, connectorized system for providing supervisory and distributed control dramatically reduces the number of wire connections that must be made to connect sensors and actuators to a control system, reducing the number of different control hardware components required to connect one or more sensors and actuators through use of a configurable I/O module.

Claims

1. A method comprising:

(a) electrically configuring a configurable, connectorized input/output module (“

module”

) comprising a microprocessor, memory and a network interface adapted for electronic communications via one or more computer networks, the module including a control interface configurable for communicating with one or more different types and arrangements of sensors and actuators under control of a control system,

wherein the module is configured using a software configuration method,

wherein the module further comprises one or more configurable input/output pins for altering one or more electrical configurations of the module for performing one or more electrical functions using one or more control signals, wherein pathways of the control signals are configurable for providing point-to-point, controller-to-sensor or controller-to-actuator connections;

(b) electrically connecting one or more sensors or actuators to the module using the configurable input/output pins;

(c) communicating with a server computer via the network interface of the module using standard server queries via a secure connection initiated by the module for periodically transmitting control state information of the module to the server computer, wherein a response from the server computer is solicited, and

wherein communications with the server computer are initiated by the module without the module receiving polling from the server computer wherein the module is adapted to reject unsolicited messages from the server computer for communications between the server computer and the module, separate from and in addition to message rejection functions of one or more firewalls disposed in the one or more computer networks;

(d) receiving reply information transmitted from the server computer to the module, wherein the reply information includes one or more set points and controller parameters for the module; and

(e) updating the module with the one or more set points in the reply information received from the server computer only if the received reply information is responsive to the solicitation by the module, and if a configurable predetermined period of time of expiration of the one or more set points received from the server computer has not passed.

2. The method of claim 1, further comprising the step of configuring a user interface for the server computer or a computer attached to the server computer using software in the module.

3. The method of claim 1, further comprising the step of using information from the module to generate a wiring guide for the system.

4. The method of claim 1, wherein the module provides independent control in the absence of a viable connection to the server computer.

5. The method of claim 1, further comprising:

(a) setting an amount of time in which the server computer expects a transmission of control state information from the module; and

(b) raising an alarm if control state information is not transmitted to the server computer within the set amount of time.

6. The method of claim 1, wherein a plurality of modules is used and further comprising employing peer-to-peer communications between at least two of the modules.

7. The method of claim 1, wherein the set points are limited to ranges that cannot be overruled by reply information received from the server computer.

8. The method of claim 1, wherein time-based set points are pre-loaded to the module to reduce the effect of a loss of connection to the server computer.

9. The method of claim 1, wherein set points employed by the module revert to pre-set values after loss of connection to the server computer for a pre-determined time.

10. The method of claim 1, wherein the module is connected to the server computer through an internet connection.

11. The method of claim 1, wherein the module will not accept a connection request from outside a LAN in which the module is located.

12. The method of claim 1, wherein the system is located within a LAN, and no component within the LAN uses software that needs to be upgraded or supported, thereby avoiding security vulnerabilities from accepting network connections.

26. The method of claim 1 wherein the configurable input/output pins are configured using a computer file.

27. The method of claim 1 wherein the one or more computer networks comprise a cloud-based computer network.

13. An apparatus comprising:

(a) a configurable, connectorized input/output module (“

module”

) that comprises a microprocessor, memory and a network interface adapted for electronic communications via one or more computer networks, the module including a control interface configurable for communicating with one or more different types and arrangements of sensors and actuators under control of a control system,

wherein the module is configured with software,

wherein the module further comprises one or more configurable input/output pins for altering one or more electrical configurations of the module for performing one or more electrical functions using one or more control signals, wherein pathways of the control signals are configurable for providing point-to-point, controller-to-sensor or controller-to-actuator connections;

(b) one or more sensors or actuators electrically connected to the module, using the programmable input/output pins; and

(c) a server computer, in communication with the module via the network interface, the server computer adapted to communicate one or more set points and control parameters, including actuator state information, to the module via one or more solicited responses to requests from the module acting as a client of the server computer,

wherein control state information of the module is periodically transmitted to the server computer with a solicitation of a response from the server computer using standard server queries via a secure connection initiated by the module, wherein communications with the server computer are initiated by the module without the module receiving polling from the server computer wherein the module is adapted to reject unsolicited messages from the server computer for communications between the server computer and the module, separate from and in addition to message rejection functions of one or more firewalls disposed in the one or more computer networks, and the module receives reply information transmitted from the server computer to the module, the reply information including one or more set points and controller parameters for the module, and

wherein the module is updated using the one or more set points in the reply information received from the server computer only if the received reply information is responsive to the solicitation by the module, and a configurable predetermined time of expiration of the one or more set points received from the server computer has not passed.

14. The apparatus of claim 13, further comprising software to configure a user interface on the server computer or a computer attached to the server computer.

15. The apparatus of claim 13, further comprising information from the apparatus to generate a wiring guide for the apparatus.

16. The apparatus of claim 13, wherein the module provides independent control of the apparatus system in the absence of a viable connection to the server.

17. The apparatus of claim 13, wherein a plurality of modules is used and there are peer-to-peer connections between at least two of the modules.

18. The apparatus of claim 13, wherein the set points are limited to ranges that cannot be overruled by reply information received from the server.

19. The apparatus of claim 13, wherein time-based set points are pre-loaded to the module to reduce the effect of a loss of connection to the server.

20. The apparatus of claim 13, wherein set points employed by the module revert to pre-set values after loss of connection to the server for a pre-determined time.

21. The apparatus of claim 13, wherein the module is connected to the server through an internet connection.

22. The apparatus of claim 13, wherein the module will not accept a connection request from outside a LAN in which the module is located.

23. The apparatus of claim 13, wherein the system is located within a LAN, and no component within the LAN uses software that needs to be upgraded or supported, thereby avoiding security vulnerabilities from accepting network connections.

24. The apparatus of claim 13 wherein the module is adapted to implement Supervisory Control and Data Acquisition (SCADA) and Distributed Control Systems (DCS) capabilities in a single device without a network connection to a SCADA server computer.

25. The apparatus of claim 13 wherein the module software provides a computer file for electrically configuring the configurable input/output pins in accordance with one or more sensors or actuators that are electrically connected with the module via the control interface.