Process control system and method for configuring a process control system

• US 20070073419A1
• Filed: 02/26/2004
• Published: 03/29/2007
• Est. Priority Date: 02/26/2003
• Status: Abandoned Application

• Current Assignee: Embedded Rail Technology Limited
• Original Assignee: Embedded Rail Technology Limited
• Inventors: Sesay, Sahid
• Application Number:
  US10/547,094
• Publication Number:
  US 20070073419A1
• Time in Patent Office: Days
• US Class Current: 700/18
• CPC Class Codes: G05B 19/05 Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
• CPC Class Codes: G05B 2219/24103 Graphical display of proces as function of detected alarm signals
• CPC Class Codes: G05B 2219/24123 Alarm filtering, level and direct precursor, required action, blocking condition

Abstract

A process control system comprising: a programmable automation controller; and at least one process control peripheral. Each process control peripheral is in data and control communication with the programmable automation controller. Upon configuration of the process control system, the programmable automation controller executes a single software program to assist a user to (i) define prescribed information in respect of the process control peripheral, including configuration information; (ii) define trigger conditions, if any, associated with the process control peripheral; and (iii) define alarm conditions, if any, associated with the process control peripheral. Once configured, the software program is operable to provide information in respect of the process control system to the user.

Claims

1. A process control system comprising a programmable automation controller and at least one process control peripheral, each process control peripheral in data and control communication with the programmable automation controller, wherein, upon configuration of the process control system, the programmable automation controller executes a single software program to assist a user to

define prescribed information in respect of the process control peripheral, including configuration information;

define trigger conditions, if any, associated with the process control peripheral; and

define alarm conditions, if any, associated with the process control peripheral,

the software program thereafter being operable to provide information in respect of the process control system to the user.

2. A process control system according to claim 1 wherein the prescribed information includes high and low raw input values.

3. A process control system according to claim 1, wherein, if the process control peripheral is, at least in part, a digital device, the prescribed information includes default device state information.

4. A process control system according to claim 1 wherein, if the process control peripheral is, at least in part, an analogue device, the prescribed information includes high and low engineering values and measurement increment information.

5. A process control system according to claim 1 wherein the prescribed information includes at least one of the following:

details of whether the process control peripheral is bipolar;

details of whether the process control peripheral is a DE device;

default output value.

6. A process control system according to claim 1 wherein the software program is operable to scan all input/output ports of the programmable automation controller for process control peripherals and obtain predetermined details regarding each process control peripheral detected.

7. A process control system according to claim 6 wherein the software program is further operable to provide the predetermined details in respect of each detected process control peripheral to the user and receive confirmation from the user that the predetermined details correspond with the process control peripherals in data and control communication with the programmable automation controller.

8. A process control system according to claim 1 wherein the software program is operable to assist the user to define a channel through which each process control peripheral sends data and control communications to the programmable automation controller.

9. A process control system according to claim 6 wherein the predetermined details includes details of a channel through which each process control peripheral sends data and control communication to the programmable automation controller.

10. A process control system according to claim 1 wherein the software program is operable to assist the user to define at least one environment and to associate a shape with each defined environment.

11. A process control system according to claim 10 wherein the prescribed information includes details of the environment to which the process control peripheral relates.

12. A process control system according to claim 1 wherein the prescribed information includes an image to be used to represent the process control peripheral.

13. A process control system according to claim 12, wherein the software program is operable to assist the user to define at least one environment and to associate a shape with each defined environment and the prescribed information includes details of the environment to which the process control peripheral relates, including a display means in data communication with the programmable automation controller, the display means operable to display the image used to represent each process control peripheral within the display of the shape associated with the environment to which the process control peripheral relates, the user thereafter able to re-configure or view data on the operation of the process control system by appropriate manipulation of each image or shape.

14. A process control system according to claim 1 wherein the programmable automation controller includes a database and the prescribed information includes an indication as to whether values recorded by the process control peripheral are to be logged in the database

15. A process control system according to claim 14 wherein the prescribed information includes details of the time interval to expire between logging values in the database.

16. A process control system according to claim 1 wherein the prescribed information includes details of the active state of the process control peripheral and, the software program is operable to assist the user to schedule when the process control peripheral is to change to the active state.

17. A process control system according to claim 1 wherein the prescribed information includes:

an indication of whether the process control peripheral is the subject of an alarm; and

an indication of whether the process control peripheral is the subject of, or catalyst for, a trigger condition.

18. A process control system according to claim 17 wherein the software program is operable to verify that each process control peripheral indicated as being the subject of an alarm is the subject of a defined alarm condition and that each process control peripheral indicated as being the subject of, or catalyst for, a trigger condition is the subject of, or catalyst for, a defined trigger condition.

19. A process control system according to claim 1 wherein a defined alarm condition includes details of the method of alarm.

20. A process control system according to claim 19 wherein the method of alarm includes at least one of the following:

Short Message Service message;

e-mail;

pager;

speaker;

phone.

21. A process control system according to claim 1 wherein the defined trigger condition includes details of the time period to elapse before rechecking the trigger condition and a response, the response being initiated if the trigger condition still exists on rechecking.

22. A process control system according to claim 1 wherein the software program includes means for simulating the operation of the process control system.

23. A process control system according to claim 1 wherein each process control peripheral is one of:

sensor, actuator or camera.

24. A process control system according to claim 1 wherein data and control communication accords with a non-proprietary communication protocol.

25. A process control system according to claim 1 wherein data and control communication is effected by one of the following means:

cable, wireless, infrared or PCI/ISA card.

26. A process control system according to claim 1 wherein the user is located remote to the programmable automation controller and the single software program is adapted to assist the user via a remote computer.

27. A process control system according to claim 1 wherein the remote computer is one of the following:

notebook computer;

hand-held PC;

personal digital assistant;

tablet PC;

desktop PC;

mobile phone.

28. A method for configuring a process control system comprising:

establishing data and control communication between a programmable automation controller and at least one process control peripheral; and

defining prescribed information in respect of the process control peripheral, including configuration information, via a single software program;

defining trigger conditions, if any, associated with the process control peripheral using the software program; and

defining alarm conditions, if any, associated with the process control peripheral using the software program.

29. A method for configuring a process control system according to claim 28, wherein the step of defining the prescribed information includes the step of defining high and low raw input values.

30. A method for configuring a process control system according to claim 28 wherein the step of defining the prescribed information includes the step of defining default device state information if the process control peripheral is, at least in part, a digital device.

31. A method for configuring a process control system according to claim 28 wherein the step of defining the prescribed information includes the step of defining high and low engineering values and measurement increment information if the process control peripheral is, at least in part, an analogue device.

32. A method for configuring a process control system according to claim 28 wherein the step of defining the prescribed information includes the step of defining at least one of the following:

details of whether the process control peripheral is bipolar;

details of whether the process control peripheral is a DE device;

default output value.

33. A method for configuring a process control system according to claim 28 further including the steps of scanning all input/output ports of the programmable automation control for process control peripherals;

and obtaining predetermined details regarding each process control peripheral detected.

34. A method for configuring a process control system according to claim 33 further including the steps of providing the predetermined details in respect of each detected process control peripheral to the user;

and receiving confirmation from the user that the predetermined details correspond with the process control peripherals in data and control communication with the programmable automation controller.

35. A method for configuring a process control system according to claim 28, including the step of, for each process control peripheral, defining a channel through which the process control peripheral sends data and control communications to the programmable automation controller using the software program.

36. A method for configuring a process control system according to claim 33 including the step of automatically identifying each channel through which each process control peripheral send data and control communication to the programmable automation controller and providing that information as part of the determined details.

37. A method for configuring a process control system according to claim 28 including the steps of defining at least one environment and associating a shape with each defined environment.

38. A method for configuring a process control system according to claim 37 including the step of associating each process control peripheral with a defined environment.

39. A method for configuring a process control system according to claim 28 including the step of defining an image to be used to represent the process control peripheral.

40. A method for configuring a process control system according to claim 39, including the steps of defining at least one environment and associating a shape with each defined environment;

associating each process control peripheral with a defined environment; and

displaying, for each process control peripheral, the image used to represent each process control peripheral within the display of the shape associated with the environment to which the process control peripheral relates.

41. A method for configuring a process control system according to claim 28 including the step of indicating whether values recorded by the process control peripheral are to be logged in a database.

42. A method for configuring a process control system according to claim 41 including the step of defining the time interval to expire between logging of values in the database.

43. A method for configuring a process control system according to claim 28 including the additional steps of detailing the active state of the process control peripheral and, using the software, assisting the user to schedule when the process control peripheral is to change to the active state.

44. A method for configuring a process control system according to claim 28 including the additional steps of indicating whether the process control peripheral is the subject of an alarm;

and indicating whether the process control peripheral is the subject of, or catalyst for, a trigger condition.

45. A method for configuring a process control system according to claim 44 including the steps of verifying that each process control peripheral indicated as being the subject of an alarm is the subject of a defined alarm condition;

and verifying that each process control peripheral indicated as being the subject of, or catalyst for, a trigger condition is the subject of, or catalyst for, a defined trigger condition.

46. A method for configuring a process control system according to claim 28 including the step of defining a method of alarm from one of the following:

Short Message Service message;

e-mail;

pager;

speaker;

phone.

47. A method for configuring a process control system according to claim 28 including the steps of detailing a time period to elapse before rechecking the trigger condition and a response to the trigger condition and initiating the response if the trigger condition still exists on rechecking.

48. A programmable automation controller for use in a process control system, the programmable automation controller in data and control communication with at least one process control peripheral, the programmable automation controller being operable to execute a single software program to assist a user to:

define prescribed information in respect of each process control peripheral, including configuration information;

define trigger conditions, if any, associated with the process control peripheral; and

define alarm conditions, if any, associated with the process control peripheral

the software program thereafter being operable to provide information in respect of the process control system to the user.

49. A programmable automation controller according to claim 48 wherein the software program is operable to scan all input/output ports of the programmable automation controller for process control peripherals and obtain predetermine details regarding each process control peripheral detected.

50. A programmable automation controller according to claim 49 wherein the software program is operable to provide the predetermined details in respect of each detected process control peripheral to the user and receive confirmation from the user that the predetermined details correspond with the process control peripherals in data and control communication with the programmable automation controller.

51. A programmable automation controller according to claim 48 wherein the software program is operable to assist the user to define a channel through which each process control peripheral sends data and control communication to the programmable automation controller.

52. A programmable automation controller according to claim 48 wherein the software program is operable to assist the user to define at least one environment and to associate a shape with each defined environment.

53. A programmable automation controller according to claim 52, wherein the software program is operable to display on a display means an image used to represent each process control peripheral within the display of the shape associated with the environment to which the process control peripheral relates.

54. A programmable automation controller according to claim 48 including a database for recording values recorded by prescribed process control peripherals.

55. A programmable automation controller according to claim 48 wherein the software program is operable to verify that each process control peripheral indicated as being the subject of an alarm is the subject of a defined alarm condition and that each process control peripheral indicated as being the subject of, or catalyst for, a trigger condition is the subject, or defined catalyst for, a defined trigger condition.

56. A programmable automation controller according to claim 48 wherein the software program includes means for simulating the operation of the process control system.

57. A programmable automation controller according to claim 48 wherein data and control communication with the at least one process control peripheral accords with a non-proprietary communication protocol.

58. A programmable automation controller according to claim 48 wherein data and control communication with the at least one process control peripheral is effected by at least one of the following means:

cable, wireless, infrared or PCI/ISA card.

59. A programmable automation controller according to claim 48 wherein the software program is adapted to assist the user located remote to the programmable automation controller via a remote computer.

60. A computer for use in a process control system, the computer in data and control communication with at least one remote programmable automation controller, the at least one remote programmable automation controller in data and control communication with at least one process control peripheral, wherein, upon configuration of the process control system, the at least one remote programmable automation controller executes a single software program to assist a user of the computer to:

define prescribed information in respect of the at least one process control peripheral, including configuration information;

define trigger conditions, if any, associated with the at least one process control peripheral; and

define alarm conditions, if any, associated with the process control peripheral, the software program thereafter being operable to provide information in respect of the process control system to the user via the computer.

61. (canceled)

62. (canceled)

63. (canceled)

64. (canceled)