Distributed control system diagnostic logging system and method

• US 20070078629A1
• Filed: 09/30/2005
• Published: 04/05/2007
• Est. Priority Date: 09/30/2005
• Status: Abandoned Application

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Gollhardt, Neil, Wielebski, Wayne
• Application Number:
  US11/241,018
• Publication Number:
  US 20070078629A1
• Time in Patent Office: Days
• US Class Current: 702/183
• CPC Class Codes: G05B 2219/24055 Trace, store a working, operation history
• CPC Class Codes: G05B 2219/31324 Distributed real time knowledge, database
• CPC Class Codes: G05B 2219/31337 Failure information database
• CPC Class Codes: G05B 2219/31356 Automatic fault detection and isolation
• CPC Class Codes: G05B 2219/35291 Record history, log, journal, audit of machine operation
• CPC Class Codes: G05B 2223/06 Remote monitoring
• CPC Class Codes: G05B 23/0208 characterized by the configuration of the monitoring system
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A logging system is provided for a distributed automation application, such as an on-machine motor controller or the like. The logging system can access raw data, processed data, event data, error data, and so forth from a controller local to the applicational power to a load, such as an electric motor. The logging system can also access information and place information on a network to which the controller is linked. Logging system may also monitor and log data directly from sensors. Information and data stored in logging system may be interrogated and accessed either remotely via a network, or locally, such as through a local access port.

Claims

1. An on-machine diagnostic logging system comprising:

interface circuitry for receiving control and monitoring signals from machine control devices that control or monitor operation of a machine system;

a processor for receiving the control and monitoring signals from the interface and for processing the signals at least partially independently of a remote control and monitoring system; and

a memory circuit for storing the control and monitoring signals received by the processor;

wherein a subset of the control and monitoring signals are transmitted to the remote control and monitoring system, and the diagnostic logging system receives and stores signals not part of the subset, and wherein the interface circuitry is configured to be interrogated for access to control and monitoring signals stored in the memory circuit.

2. The system of claim 1, wherein the interface circuitry is configured to be coupled to a network and to monitor signals on the network for extraction of the control and monitoring signals to be stored in the memory circuit.

3. The system of claim 1, wherein the interface circuitry is addressable via a network for remote access to the control and monitoring signals stored in the memory circuit.

4. The system of claim 1, wherein the interface circuitry is configured to receive analog control or monitoring signals applied to or sensed from a controlled machine system.

5. The system of claim 1, wherein the processor is configured to perform analysis of the received control and monitoring signals to determine fault or error conditions in the controlled machine system.

6. The system of claim 1, wherein the system is configured to log signals passively only without communication of output or control signals to the controlled machine system.

7. The system of claim 1, wherein the system is disposed in a tamper-proof module coupled locally to a logging point of the controlled machine system.

8. An on-machine diagnostic logging system comprising:

interface circuitry for receiving control and monitoring signals from a motor controller that controls or monitor operation of a motor of a machine system;

a processor for receiving the control and monitoring signals from the interface and for processing the signals at least partially independently of a remote control and monitoring system; and

a memory circuit for storing the control and monitoring signals received by the processor;

wherein the logging system is configured as an independently operating module configured to be physically located proximate to the controller and local to the motor, and the interface circuitry is configured to be interrogated for access to control and monitoring signals stored in the memory circuit.

9. The system of claim 8, wherein a subset of the control and monitoring signals are transmitted to a remote control and monitoring system, and the diagnostic logging system receives and stores signals not part of the subset.

10. The system of claim 8, wherein the interface circuitry is configured to be coupled to a network and to monitor signals on the network for extraction of the control and monitoring signals to be stored in the memory circuit.

11. The system of claim 8, wherein the interface circuitry is coupled to a local access port for extraction of the control and monitoring signals to be stored in the memory circuit locally via the local access port.

12. The system of claim 8, wherein the interface circuitry is addressable via a network for remote access to the control and monitoring signals stored in the memory circuit.

13. The system of claim 8, wherein the interface circuitry is configured to receive analog control or monitoring signals applied to or sensed from a controlled machine system.

14. The system of claim 8, wherein the processor is configured to perform analysis of the received control and monitoring signals to determine fault or error conditions in the controlled machine system.

15. The system of claim 8, wherein the system is configured to log signals passively only, without communication of output or control signals to the controller.

16. An on-machine diagnostic logging system comprising:

a motor controller mounted locally to a controlled motor of a controlled machine system for controlling operation of the motor; and

a diagnostic logging module disposed physically proximate the motor controller and including interface circuitry for receiving control and monitoring signals from the motor controller, a processor for receiving the control and monitoring signals from the interface and for processing the signals at least partially independently of a remote control and monitoring system, and a memory circuit for storing the control and monitoring signals received by the processor;

wherein the logging module operates independently of the motor controller, and the interface circuitry is configured to be interrogated for access to control and monitoring signals stored in the memory circuit.

17. The system of claim 16, wherein the motor controller and the diagnostic logging module are disposed in a common enclosure.

18. The system of claim 16, wherein a subset of the control and monitoring signals are transmitted to a remote control and monitoring system, and the diagnostic logging module receives and stores signals not part of the subset.

19. The system of claim 16, wherein the interface circuitry is configured to be coupled to a network and to monitor signals on the network for extraction of the control and monitoring signals to be stored in the memory circuit.

20. The system of claim 16, wherein the interface circuitry is coupled to a local access port for extraction of the control and monitoring signals to be stored in the memory circuit locally via the local access port.