Modular programmable automation controller with multi-processor architecture

• US 20050220127A1
• Filed: 03/22/2005
• Published: 10/06/2005
• Est. Priority Date: 03/22/2004
• Status: Active Grant

• Current Assignee: Fairmount Automation, Inc. (Enovis Corp.)
• Original Assignee: Fairmount Automation, Inc. (Enovis Corp.)
• Inventors: Kelsey, Patrick J., Cane, Gary R., Lebaudy, Andres, Stolzenberg, Jay
• Granted Patent: US 7,774,073 B2
• Time in Patent Office: Days
• US Class Current: 370/410
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: H04L 43/00 Arrangements for monitoring or testing data switching networks

Abstract

An apparatus and method for forming a control node in a programmable architecture, is disclosed. The node includes a plurality of user-programmable, microprocessor-based modules connected together. The modules are connected to create a parallel-processing environment with a selected functionality. Hot-swapping of the modules can be determined in the node. Power is distributed throughout the modules in the node. The modules may be automatically programmed to accommodate a target independent device.

Claims

1. A method for forming a control node, the method comprising:

providing a plurality of modules, each module including an independently operating, user-programmable microprocessor and associated set of hardware resources;

connecting the modules so that the modules can communicate with one another;

selecting a master module from the plurality of modules and identifying the remaining module(s) as slave module(s); and

,

determining an address of each of the salve module(s).

2. The method of claim 1, further comprising detecting whether any one of the plurality of modules has been hot-swapped into or out of the node.

3. The method of claim 1, further comprising automatically programming the module.

4. The method of claim 1, further comprising distributing power to the plurality of modules.

5. The method of claim 1, wherein the step of selecting a master module includes sharing a single multi-drop serial channel amongst the plurality of modules.

6. The method of claim 5, further comprising allowing only one module to transmit at a designated time.

7. The method of claim 1, wherein the step of selecting a mast module comprises selecting the right most module in the node as the master module.

8. The method of claim 1, further comprising employing an array of series-connected resistors, with one resistor per module, wherein the leftmost end of the array is grounded, and a constant current source is connected to the right most end of the array.

9. The method of claim 1, wherein the step of determining an address comprises sampling a voltage drop across the master module and providing the voltage drop to the slave modules.

10. The method of claim 1, wherein the step of determining an address further comprises using an array of series-connected resistors in the node position chain and determining the address by a Voltage Per Module/(I*R).

11. The method of claim 1, further comprising a backplane initialization:

closing a node position actuator for each module;

determining whether any module has been hot-swapped by monitoring a communication channel of a backplane for a predetermined period of time;

broadcasting a command from the master module to all other modules in the node to determine their respective address; and

distributing a node configuration file from the master module to all remaining modules in the node.

12. The method of claim 11, wherein detecting whether the module has been hot-swapped comprises:

monitoring a voltage at the master module to ascertain any change, wherein a node sense actuator is added to each module and is used for detecting the voltage charge to a module corresponding to an address in the full left position of the node;

detecting removal of the master module after monitoring the voltage the master module; and

detecting removal of other modules after monitoring the voltage at the master module.

13. The method of claim 11, further comprising reinitializing the node when a new master module is inserted.

14. The method of claim 1, further comprising:

distributing a node configuration file to every module in the node on initial programming;

storing the node configuration file in non-volatile memory of each module; and

employing the node configuration file in the modules and programming a newly added module.

15. The method of claim 1, further comprising:

introducing power into the node via at least one pre-regulating module;

outputting a predetermined voltage from the pre-regulating module to other modules in the node; and

post-regulating the power from the pre-regulating module using the other modules in the node.

16. The method of claim 1, further comprising adding a plurality of pre-regulating modules to the node and providing power redundancy and power sharing.

17. The method of claim 1, further comprising:

creating hardware-link information for allowing a user to reuse a program on different hardware platforms;

allowing the program to link to at least one module in the node; and

allowing a generic hardware element to link to hardware in the module the program is linked to, and to adjunct hardware located in other remaining modules in the node.

18. A control node, comprising:

a plurality of modules, each module including an independently operating, user-programmable microprocessor;

a node position chain to provide communication between the plurality of modules; and

,

a node position actuator in each module.

19. The control node of claim 18, wherein the node position chain includes an array of series-connected resistors, with one resistor per module.

20. The control node of claim 18, each of the plurality of modules including a means for determining a voltage at the module, wherein each module determines if it is a master module based on the voltage across the module.

21. The control node of claim 18, wherein the module determines that it is the master module if there is a voltage at the module.

22. The control node of claim 18, wherein the module determines that it is a slave module if there is no voltage at the module.

23. The control node of claim 18, wherein one module is connected to a current source and one module is connected to ground.