Method and a tool for allocating computational resources in a distributed control system

• US 20060155392A1
• Filed: 06/02/2003
• Published: 07/13/2006
• Est. Priority Date: 06/02/2003
• Status: Abandoned Application

• Current Assignee: ABB Research Ltd. (ABB Ltd.)
• Original Assignee: ABB Research Ltd. (ABB Ltd.)
• Inventors: Wendt, Peter, Fay, Alexander, Lorito, Fabrizio, Poretta, Stefano, Vahldieck, Rolf
• Application Number:
  US10/559,080
• Publication Number:
  US 20060155392A1
• Time in Patent Office: Days
• US Class Current: 700/18
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 2219/23293 Automated assembly of machine control software, reusable software components
• CPC Class Codes: G05B 2219/23424 Select construction element from function library
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention concerns method and a tool for designing an optimal hardware structure of a process control system and configuring a given control function onto the optimal hardware structure of the process control system. The method and the tool of the invention comprises three main parts that can be used in conjunction or be used separately together with other solutions for the remaining part or parts of the system.

Claims

1-27. -27. (canceled)

28. A method for designing and distributing a process control system, wherein the control system comprises a software structure and a hardware structure including components comprising field devices, controllers, linking devices, the method comprising:

using a predefined complete control function and searching a software library comprising computational capability and description characteristics of hardware components and automatically designing an optimal hardware structure for the process control system;

automatic generation of executable code and configuration of the complete control function on to the designed optimal process control hardware structure; and

automatic assignment of HW addresses and configuration of the linking devices.

35. The method of claim 28, wherein the automatic configuration includes switching on or off executable code already present in field devices.

36. The method of claim 28, wherein the automatically designed optimal hardware structure is shown in such a way that it is capable of being altered by an operator before the generation of code and configuration takes place.

37. The method of claim 28, further comprising issuing a bill of material after the optimal process control hardware structure has been designed either automatically or after alteration by an operator.

38. The method of claim 28, wherein a configuration algorithm takes into account HW costs, HW speed, communication bandwidth and communication speed, real-time criteria, computation needs including memory and time, of the control functions as well as proximity to field devices including sensors and actuators.

39. The method of claim 28, wherein the process control system hardware structure comprises both wired and non-wired field devices.

29. A method for automatic design of an optimal hardware structure for a given control function for a process control system, the method comprising:

using the given control function and searching a software library comprising computational capability and description characteristics of hardware components; and

automatically designing an optimal hardware structure for the process control system responsive to the search results.

32. The method of claim 29, further comprising automatically distributing the given control function onto the optimal hardware structure of the process control system by automatic generation of executable code and distribution of the given control function on to the optimal process control hardware structure.

33. The method of claim 29, further comprising implementing a communication function after distribution of a given control function onto the optimal hardware structure by automatic assignment of HW addresses and configuration of linking devices.

55. The method of claim 29, wherein the automatic configuration includes switching on or off executable code already present in field devices.

57. The method of claim 29, wherein the automatically designed optimal hardware structure is shown in such a way that it is capable of being altered by an operator before the generation of code and configuration takes place.

58. The method of claim 29, further comprising issuing a bill of material after the optimal process control hardware structure has been designed either automatically or after alteration by an operator.

59. The method of claim 29, wherein a configuration algorithm takes into account HW costs, HW speed, communication bandwidth and communication speed, real-time criteria, computation needs including memory and time, of the control functions as well as proximity to field devices including sensors and actuators.

61. The method of claim 29, wherein the process control system hardware structure comprises both wired and non-wired field devices.

30. A method for automatic distribution of a given control function onto a given hardware structure of a process control system, the method comprising automatically generating and distributing executable code of the given control function on to the given process control hardware structure.

34. The method of claim 30, further comprising implementing a communication function for the given control function for the given process control hardware structure by automatic assignment of HW addresses and configuration of linking devices.

56. The method of claim 30, wherein the automatic configuration includes switching on or off executable code already present in field devices.

60. The method of claim 30, wherein a configuration algorithm takes into account HW costs, HW speed, communication bandwidth and communication speed, real-time criteria, computation needs including memory and time, of the control functions as well as proximity to field devices including sensors and actuators.

62. The method of claim 30, wherein the process control system hardware structure comprises both wired and non-wired field devices.

31. A method for implementing a communication function for a given control function for a given process control hardware structure, the method comprising automatically assigning HW addresses and configuring linking devices.

63. The method of claim 31, wherein the process control system hardware structure comprises both wired and non-wired field devices.

40. A method for designing and configuring a process control system in operation after a failure of a component, wherein the control system comprises a complete control function, a software structure and a hardware structure including components including field devices, controllers, linking devices, the method comprising:

automatically detecting a failure of a hardware component; and

using the complete control function and searching a software library comprising computational capability and description characteristics of hardware components;

automatically designing a new optimal hardware structure for the process control system excluding the failed hardware component;

automatically generating executable code that distributes the control function to the new hardware structure; and

automatically assigning HW addresses to new components of the hardware structure and configuring the linking devices.

41. A computer-implemented device for defining and configuring computational resources in a process control system, wherein the control system comprises a software structure and a hardware structure including field devices, controllers, and linking devices, the tool comprising:

a software library comprising computational capability and description characteristics of hardware components useful to automatically design an optimal hardware structure for a given process control function;

an automatic tool starting from the complete control function that searches the software library and automatically designs an optimal hardware structure for the process control system;

a distribution tool that automatically generates executable code and configuration of the complete control function on to the designed optimal process control hardware structure; and

a tool that automatically assigns HW addresses and configuration of the linking devices.

48. The computer-implemented device of claim 41, wherein the tool that automatically assigns HW addresses and configuration of the linking devices includes means for switching on or off executable code already present in field devices.

50. The computer-implemented device of claim 41, wherein the software library includes predefined constraints on parameters characterizing hardware components of the control system including spare parts and cost parameters.

51. The computer-implemented device of claim 50, wherein the automatic tool includes capability of exploiting intrinsic redundancy present in a fieldbus system in order to ensure effective redundancy during operation.

52. The computer-implemented device of claim 41, further comprising:

means for generating a new hardware structure based on non-failing parts of the system; and

means for automatically distributing the control function on to the new hardware structure in response to a failure of a hardware component or corresponding software.

53. The computer-implemented device of claim 41, further comprising means for issuing a bill of material after an optimal process control hardware structure is designed.

54. The computer-implemented device of claim 41, wherein a configuration algorithm of the distribution tool takes into account factors comprising HW costs, HW speed, communication bandwidth, communication speed, real-time criteria, memory, and processing time of the given process control function and proximity to field devices including sensors and actuators.

42. A system for automatic design of an optimal hardware structure for a given control function for a process control system, the automatic design system comprising:

an automatic tool, wherein the automatic tool uses the given control function and searches a software library comprising computational capability and description characteristics of hardware components, and automatically designs an optimal hardware structure for the process control system responsive to search results.

45. The apparatus of claim 42, further comprising means for automatic distribution of the given control function onto the given hardware structure of the process control system, wherein the means for automatic distribution comprises a distribution tool that automatically generates executable code and distributes the given control function onto the given process control hardware structure.

46. The apparatus of claim 42, further comprising means for implementing a communication function for a given control function for a given process control hardware structure, wherein the means for implementing comprises a tool that automatically assigns HW addresses and configuration of linking devices.

49. The system of claim 42, further comprising means for showing an automatically designed optimal hardware structure and means for altering the structure by an operator before generation of code and configuration takes place.

64. The system of claim 42, wherein the software library includes predefined constraints on parameters characterizing hardware components of the control system including spare parts and cost parameters.

43. An apparatus for automatic distribution of a given control function onto a given hardware structure of a process control system, the apparatus comprising a distribution tool that automatically generates executable code and distributes the given control function on to the given process control hardware structure.

47. The apparatus of claim 43, further comprising means for implementing a communication function for a given control function for a given process control hardware structure, wherein the means for implementing comprises a tool that automatically assigns HW addresses and configuration of linking devices.

44. An apparatus means for implementing a communication function for a given control function for a given process control hardware structure, the apparatus comprising tool that automatically assigns HW addresses and configuration of linking devices.