Flexible input/output devices for use in process control systems

• US 20080080395A1
• Filed: 09/29/2006
• Published: 04/03/2008
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Eddie, Ronald Dean, Snead, Thomas W., Law, Gary Keith, Schleiss, Trevor Duncan, Burr, Kent
• Granted Patent: US 8,761,196 B2
• Time in Patent Office: Days
• US Class Current: 370/254
• CPC Class Codes: G05B 19/4186 by protocol, e.g. MAP, TOP
• CPC Class Codes: G05B 2219/31181 Controller and device have several formats and protocols, select common one
• CPC Class Codes: H04L 41/0803 Configuration setting
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

Methods, apparatus and articles of manufacture are disclosed that provide flexible input/output device communications in a process control system. In one example, a process control system controls a plurality of field devices. The process control system includes a control device and a communications protocol component. The communications protocol component has at least one communications channel that is selectively configurable to use at least a first or second communications protocol and to communicate with at least one of the field devices.

Claims

1. A process control system to control a plurality of field devices, the process control system comprising a control device and a communications protocol component having at least one communications channel that is selectively configurable to use a first or second communications protocol and to communicate with at least one of the field devices.

2. A process control system as defined in claim 1, wherein the communications protocol component has a first channel and a second channel and the first channel is configured to use the first communications protocol and the second channel is configured to use the second communications protocol.

3. A process control system as defined in claim 2, wherein the first and second channels are to use the first and second communication protocols, respectively, simultaneously.

4. A process control system as defined in claim 1, wherein the first or the second communications protocol is selectable for each of a plurality of communication channels associated with the field devices.

5. A process control system as defined in claim 1, wherein the first channel is coupled to a first one of the field devices and the second channel is coupled to a second one of the field devices.

6. A process control system as defined in claim 1, wherein the control device is configured to assign addresses to the field devices.

7. A process control system as defined in claim 1 further comprising a handheld configuration tool, wherein the handheld configuration tool is configured to assign addresses to the field devices.

8. A process control system as defined in claim 1, wherein the communications protocol component resides on an input/output device that is coupled to the control device, and wherein the communications protocol component is configured using a configuration application associated with the process control system.

9. A process control system as defined in claim 8, wherein the configuration application is created using one tool.

10. A process control system as defined in claim 9, wherein the tool is an application configured to be executed via a workstation.

11. A process control system as defined in claim 8, wherein the configuration application is incorporated within an object-oriented database.

12. A process control system as defined in claim 8, wherein the configuration application is self-documenting.

13. A process control system as defined in claim 8, wherein the configuration application provides information related to the sensing of the field devices by the input/output device.

14. A process control system as defined in claim 8, wherein the configuration application is configured to clear address assignments of the field devices.

15. A process control system as defined in claim 8, wherein the configuration application is configured to use a device definition to describe an input, an output, or a parameter associated with a particular one of the field devices.

16. A process control system as defined in claim 15, wherein the device definition is imported into a configuration database in a bulk format or through a user creation.

17. A process control system as defined in claim 15, wherein the device definition is generated using a product description.

18. A process control system as defined in claim 15, wherein the device definition is created as the particular one of the field devices is added to the process control system.

19. A process control system as defined in claim 15, wherein cues for creating the device definition are provided to a user based on a communications protocol used to communicate with the particular one of the field devices.

20. A process control system as defined in claim 15, wherein the configuration application is configured to generate signal tags with labels related to the device definition.

21. A process control system as defined in claim 8, wherein the configuration application is configured to generate device alerts on a per field device basis for any one of a plurality of communication protocols used to communicate with the field devices.

22. A process control system as defined in claim 8, wherein the process control system is configured to use the input/output device and a redundant input/output device.

23. A process control system as defined in claim 8, wherein the configuration application supports pass-through communications from a workstation-based device configuration application.

24. An input/output device for use in a process control system, the input/output device comprising at least a first communications channel to establish communications between at least one of a plurality of field devices and a control device using at least one of a first available communications protocol or a second available communications protocol.

25. An input/output device as defined in claim 24, further comprising a second communications channel, wherein the first communications channel is to use the first communications protocol and the second communications channel is to communicate between at least one of the plurality of field devices and the control device using the second communications protocol.

26. An input/output device as defined in claim 25, wherein the first and second channels are to use the first and second communication protocols, respectively, simultaneously.

27. An input/output device as defined in claim 25, wherein the first communications channel is coupled to a first one of the plurality of field devices and the second communications channel is coupled to a second one of the plurality of field devices.

28. An input/output device as defined in claim 24, wherein the first or second communications protocol is selectable for each of the plurality of field devices.

29. An input/output device as defined in claim 24, wherein the input/output device is configurable remotely.

30. An input/output device as defined in claim 24, wherein the input/output device is configured to automatically sense the field devices.

31. A method of controlling a plurality of field devices, the method comprising:

initializing an input/output device that includes a communications protocol component having at least one communications channel;

configuring the at least one communications channel to use at least a first available communications protocol or a second available communications protocol; and

communicating with one of the field devices via the at least one communications channel using the at least first communications protocol or second communications protocol.

32. A method as defined in claim 31, further comprising configuring a second communications channel and communicating with the field devices via the first communications channel using the first communications protocol and via the second communications channel using the second communications protocol.

33. A method as defined in claim 32, wherein the first and second channels use the first and second communication protocols, respectively, simultaneously.

34. A method as defined in claim 31 further comprising selectively configuring the input/output device to use the first communications protocol or the second communications protocol for each of the plurality of field devices.

35. A method as defined in claim 31, wherein a first communications channel enables communications with a first field device and a second communications channel enables communications with a second field device.

36. A method as defined in claim 31 further comprising using a control device to assign addresses to the field devices.

37. A method as defined in claim 31 further comprising using a handheld configuration tool to assign addresses to the field devices when a control system is offline.

38. A method as defined in claim 31 further comprising configuring the communications protocol component by extending a configuration application associated with a control system.

39. A method as defined in claim 38 further comprising creating the configuration application using a single tool.

40. A method as defined in claim 39, wherein the tool is an application running on a workstation.

41. A method as defined in claim 38 further comprising incorporating the configuration application into a single object-oriented database.

42. A method as defined in claim 38, wherein the configuration application is self-documenting.

43. A method as defined in claim 38 further comprising using the configuration application to provide information related to the sensing of the field devices by an interface card.

44. A method as defined in claim 38 further comprising using the configuration application to clear address assignments of the field devices.

45. A method as defined in claim 38, wherein the configuration application uses a device definition to describe an input, an output, or a parameter of a particular one of the field devices.

46. A method as defined in claim 45 further comprising importing the device definition into a configuration database in a bulk format or via an interaction with a user.

47. A method as defined in claim 46, wherein the user creates the device definition from a product description.

48. A method as defined in claim 45, wherein the user creates the device definition as the particular one of the field devices is added to the control system.

49. A method as defined in claim 45 further comprising providing cues for creating the device definition to the user based on the communications protocol used to communicate with the particular one of the field devices.

50. A method as defined in claim 45 further comprising using the configuration application to generate signal tags with labels related to the device definition.

51. A method as defined in claim 38 further comprising using the configuration application to generate device alerts on a per field device basis for any one of a plurality of communication protocols.

52. A method as defined in claim 31 further comprising supporting redundant interface cards.

53. A method as defined in claim 31 further comprising supporting pass-through communications from a workstation-based device configuration application.

54. A machine accessible medium having data stored thereon that, when accessed, causes a machine to control at least one of a plurality of field devices by:

initializing an input/output device that includes a communications protocol component having at least one communications channel;

configuring the at least one communications channel to use at least a first available communications protocol or a second available communications protocol; and

communicating with one of the field devices via the at least one communications channel using the first communications protocol or second communications protocol.

55. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to configure a second communications channel to communicate with the field devices via the first communications channel using the first communications protocol and via the second communications channel using the second communications protocol.

56. A machine accessible medium as defined in claim 55, wherein the first and second channels use the first and second communication protocols, respectively, simultaneously.

57. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to select the first communications protocol or the second communications protocol for each of the plurality of field devices.

58. A machine accessible medium as defined in claim 54, wherein the first communications channel enables communications with a first field device and the second communications channel enables communications with a second field device.

59. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to use a control device to assign addresses to the field devices.

60. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to communicate with a handheld configuration tool to assign addresses to the field devices when a control system is offline.

61. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to configure the communications protocol component by extending a configuration application associated with a control system.

62. A machine accessible medium as defined in claim 61, wherein the data stored thereon, when accessed, causes the machine to create the configuration application using a single tool.

63. A machine accessible medium as defined in claim 62, wherein the tool is an application running on a workstation.

64. A machine accessible medium as defined in claim 61, wherein the data stored thereon, when accessed, causes the machine to incorporate the configuration application into a single object-oriented database.

65. A machine accessible medium as defined in claim 61, wherein the configuration application is self-documenting.

66. A machine accessible medium as defined in claim 61, wherein the data stored thereon, when accessed, causes the machine to use the configuration application to provide information related to the sensing of the field devices by an interface card.

67. A machine accessible medium as defined in claim 61, wherein the data stored thereon, when accessed, causes the machine to use the configuration application to clear address assignments of the field devices.

68. A machine accessible medium as defined in claim 61, wherein the configuration application uses a device definition that describes an input, an output, or a parameter associated with a particular one of the field devices.

69. A machine accessible medium as defined in claim 68, wherein the data stored thereon, when accessed, causes the machine to import the device definition into a configuration database in a bulk format via interaction with a user.

70. A machine accessible medium as defined in claim 69, wherein the device definition is user generated from a product description.

71. A machine accessible medium as defined in claim 68, wherein the user creates the device definition as the one of the particular field devices is added to the process control system.

72. A machine accessible medium as defined in claim 68, wherein the data stored thereon, when accessed, causes the machine to provide cues for creating the device definition to the user based on the communications protocol used to communicate with the particular one of the field devices.

73. A machine accessible medium as defined in claim 68, wherein the data stored thereon, when accessed, causes the machine to use the configuration application to generate signal tags with labels related to the device definition.

74. A machine accessible medium as defined in claim 61, wherein the data stored thereon, when accessed, causes the machine to use the configuration application to generate device alerts on a per field device basis for any one of a plurality of communication protocols.

75. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to support redundant interface cards.

76. A machine accessible medium as defined in claim 54, wherein the data stored thereon, when accessed, causes the machine to support pass-through communications from a workstation-based device configuration application.

77. A method of using an input/output device in a process control system to communicate using a plurality of communication protocols, the method comprising:

configuring at least first one of a plurality of communication channels of the input/output device to communicate with at least one of a plurality of field devices using a first communications protocol; and

configuring at least a second one of the plurality of communication channels of the input/output device to communicate with at least another one of the plurality of field devices using a second communications protocol.

78. A method as defined in claim 77, wherein the first and second communication channels are to use the first and second communication protocols, respectively, simultaneously.

79. A method as defined in claim 77, wherein the first communications channel is coupled to a first one of the plurality of field devices and the second communications channel is coupled to a second one of the plurality of field devices.

80. A method as defined in claim 77 further comprising selecting the first communications protocol or the second communications protocol for any of the plurality of field devices on a per connection basis.

81. A method as defined in claim 77 further comprising configuring the input/output device remotely.

82. A method as defined in claim 77, wherein the input/output device is configured to automatically sense the field devices.