Industrial control system with interconnected remotely located computer control units

• US 4,304,001 A
• Filed: 01/24/1980
• Issued: 12/01/1981
• Est. Priority Date: 01/24/1980
• Status: Expired due to Term

• Current Assignee: HF Controls LP
• Original Assignee: Fornex Engineering Company
• Inventors: Cope, Michael E.
• Primary Examiner(s): Malzahn, David H.
• Application Number:
  US06/115,161
• Time in Patent Office: 677 Days
• Field of Search: 371/8, 371/32, 371/33, 371/68, 371/69, 340/200, 340/147 SC
• US Class Current: 714/4.4
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 2219/25154 Detect error, repeat transmission on error, retransmit
• CPC Class Codes: G05B 2219/25161 Only receiving station, read several times message, select correct one or reject
• CPC Class Codes: G05B 2219/25163 Transmit twice, redundant, same data on different channels, check each channel
• CPC Class Codes: G06F 11/14 Error detection or correction of the data by redundancy in operation G06F11/16 takes precedence
• CPC Class Codes: G06F 11/2205 using arrangements specific to the hardware being tested
• CPC Class Codes: G08C 25/00 Arrangements for preventing or correcting errors; Monitoring arrangements
• CPC Class Codes: H04B 17/40 of relay systems
• CPC Class Codes: H04L 1/00 Arrangements for detecting or preventing errors in the information received correcting synchronisation H04L7/00
• CPC Class Codes: H04L 1/1628 List acknowledgements, i.e. the acknowledgement message consisting of a list of identifiers, e.g. of sequence numbers H04L1/1614 takes precedence
• CPC Class Codes: H04L 1/24 Testing correct operation
• CPC Class Codes: H04L 12/417 with deterministic access, e.g. token passing

Abstract

A control system for controlling an industrial process includes a plurality of remotely located process control units (remotes) each coupled to an associated input/output device(s) and adapted to communicate with one another through a dual channel communications link. Each remote has a unique succession number within a predetermined succession order with supervisory communication-control of the communication link sequentially transferred to each remote according to its succession number to provide a revolving or master for the moment control of the system. Digital information in the form of data and control information blocks is transmitted between the remotes with the blocks transmitted twice on each channel of the communications link. The destination remote tests the block validity on one of the two dual channels and, if validated, responds with an acknowledgement signal (ACK) and, if invalid, tests the blocks on the other, alternate channel and then responds with an acknowledgement or non-acknowledgement signal (NAK) depending upon whether the data blocks tests on the alternate channel are found valid or invalid. A non-acknowledgement from the destination remote re-triggers the transmission of the blocks from the source remote. The system provides high overall operating efficiency since the remotes will maintain a system-like integrity on each side of a severed communication link and the redundant block transmission with alternate line checking provides very high information transfer reliability.

Claims

1. An information transfer system for transmitting digital information between active devices and testing the validity of the transmitted information, said system comprising:

at least one active device for transmitting information in digital form;

at least one other active device for receiving information in digital form;

plural independent communication channels connected to and extending between said first-mentioned and said second-mentioned active devices for conveying information therebetween;

said first-mentioned active device including a transmission means for transmitting digital information arranged in blocks of predetermined format, said transmission means transmitting an identical block on each of said plural communication channels; and

said second-mentioned active device including receiving means for receiving digital information transmitted by said first-mentioned active device and for selecting one of said plural communication channels and testing the validity of the received block and, when said received block from said first-selected communication channel is found invalid, for selecting another of said plural communication channels and testing the validity of the received block on said other communication channel.

2. The information transfer system claimed in claim 1 wherein:

said second-mentioned active device includes responding means for transmitting an acknowledgement signal over at least one of said channels to said first-mentioned active device when the block received over said first-selected communication channel is valid, for transmitting over at least one of said channels an acknowledgement signal to said first-mentioned active device when the block received over said other selected communication channel is found valid, and for transmitting over at least one of said channels a non-acknowledgement signal to said first-mentioned active device when the block received over said other selected communication is found invalid.

3. The information transfer system claimed in claim 2 wherein

said transmission means is responsive to the non-acknowledgement signal from said second-mentioned active device to retransmit the invalidly received block.

4. The information transfer system claimed in claim 3

including means to limit the number of retransmissions of an invalidly received block to a predetermined value.

5. The information transfer system claimed in claim 1 wherein

said transmission means is operable to transmit said block at least twice in succession on each communication channel.

6. The information transfer system claimed in claim 5 wherein:

said receiving means includes means to test the validity of the plural blocks received on a communications channel by effecting a comparison between the first-received and the second-received block.

7. The information transfer system claimed in claim 1 further comprising:

memory means for storing the block received by said receiving means on said other communication channel while the block received on said first-selected communication channel is tested for validity.

8. An information transfer system for transferring digital information between stored-program controlled means and for testing the validity of the transferred information, said system comprising:

at least one stored-program controlled means for transmitting digital information in blocks of predetermined format which blocks include an error detecting code word;

at least one other stored-program controlled means for receiving digital information in said block format and adapted to test the validity of said received block using the error detecting code word;

plural independent communication channels connected to and extending between said first-mentioned and said second-mentioned stored-program controlled means for transferring information blocks therebetween; and

said second-mentioned stored-program controlled means having validity testing means for selecting a one of said plural communication channels and testing the validity of the block received thereon and for selecting another of said plural communication channels and testing the validity of the block received on said other communication channel when the block received on said first-selected communication channel fails its validity test.

9. The information transfer system claimed in claim 8 wherein

said second-mentioned stored-program controlled means includes responding means for transmitting over at least one of said channels an acknowledgement signal to said first-mentioned stored-program controlled means when the block received over said first-selected communication channel is valid, for transmitting over at least one of said channels an acknowledgement signal to said first-mentioned stored-program controlled means when the block received over said other selected communication channel is found valid, and for transmitting over at least one of said channels a non-acknowledgement signal to said first-mentioned stored-program controlled means when the block received over said other selected communication channel is found invalid.

10. The information transfer system claimed in claim 9 wherein

said first-mentioned stored-program controlled means is responsive to the non-acknowledgement signal from said second-mentioned stored-program controlled means to retransmit the invalidly received block.

11. The information transfer system claimed in claim 10

including means to limit the number of retransmissions of an invalidity received block to a predetermined value.

12. The information transfer system claimed in claim 8 wherein

said first-mentioned stored-program controlled means is operable to transmit said block at least twice in succession on each communication channel.

13. The information transfer system claimed in claim 12 wherein:

said second-mentioned stored-program controlled means includes means to test the validity of the plural blocks received on a communications channel by effecting a comparison between the first-received and the second-received block on the channel.

14. The information transfer system claimed in claim 8 further comprising:

memory means for storing the block received on said other communication channel by said second-mentioned stored-program controlled means while the block received on said first-selected communication channel is tested for validity.

15. A system for controlling an industrial process, said system including a plurality of process controlling remotes each connected by a common communications link, said system comprising:

at least one process controlling remote for transmitting process control information in digital form, said information arranged in groups of predetermined format with each of said information groups including an error detecting code word;

at least one other process controlling remote for receiving process control information in said information group format and testing the validity of the received blocks based on said error detecting code;

the communication link interconnecting said first-mentioned and said second-mentioned remotes including at least two independent communication channels, said first-mentioned remote transmitting an identical information group on each of said communication channels, said second-mentioned remote operable to select a one of said communication channels and evaluate the validity of said received information group and select the other of said communication channels when the received information group on said first-selected communication channel fails its validity test.

16. The industrial process control system claimed in claim 15 wherein

said second-mentioned remote includes responding means for transmitting over said communications link an acknowledgement signal to said first-mentioned remote when the information group received over said first-selected communication channel is valid, for transmitting over said communications link an acknowledgement signal to said first-mentioned remote when the information group received over said other selected communication channel is found valid, and for transmitting over said communications link a non-acknowledgement signal to said first-mentioned remote when the information group received over said other selected communication channel is found invalid.

17. The industrial process control system claimed in claim 16 wherein

said first-mentioned remote is responsive to the non-acknowledgement signal from said second-mentioned remote to said first-mentioned remote to retransmit the invalidly received information group.

18. The industrial process control system claimed in claim 16

including means to limit the number of retransmissions of an invalidly received information group to a predetermined value.

19. The industrial process control system claimed in claim 15 wherein

said first-mentioned remote is operable to transmit said information groups at least twice in succession on each communication channel.

20. The industrial process control system claimed in claim 19 wherein:

said second-mentioned remote includes means to test the validity of the plural information groups received on a communications channel by effecting a comparison between the first-received and the second-received information group on the channel.

21. The industrial process control system claimed in claim 15 further comprising:

memory means for storing information groups received on said other communication channel by said second mentioned remote while the information group on said first-selected communication channel is tested for validity.

22. A system for controlling a process, said system including a plurality of process controlling remotes interconnected by a common communications link, said system comprising:

at least one process controlling remote for transmitting process control information in digital form, said information arranged in information groups of predetermined format and including an error detecting code word;

at least one other process controlling remote for receiving process control information in said information groups and testing the validity of the received groups based on said error detecting code word;

the communication link interconnecting said first-mentioned and said second-mentioned remotes including at least two independent communication channels, said first-mentioned remote transmitting identical information groups on each of said channels, said second-mentioned remote testing the validity of the received information groups on each communication channel and concluding the information transfer transaction if the received information group on at least one of said plural communication channels passes its validity check test.

23. The industrial process control system claimed in claim 22 wherein

said second-mentioned remote includes responding means for transmitting over said communications link an acknowledgement signal to said first-mentioned remote when the information group received over a first-selected communication channel is valid, for transmitting over said communications link an acknowledgement signal to said first-mentioned remote when the information group received over the other communication channel is found valid, and for transmitting over said communications link a non-acknowledgement signal to said first-mentioned remote when the information group received over said other communication channel is found invalid.

24. The industrial process control system claimed in claim 23 wherein

said first-mentioned remote is responsive to the non-acknowledgement signal from said second-mentioned remote to retransmit the invalidly received information group.

25. The industrial process control system claimed in claim 22 wherein

said first-mentioned remote is operable to transmit said information groups at least twice in succession on each communication channel.

26. The industrial process control system claimed in claim 25 wherein

said second-mentioned remote includes means to test the validity of the plural information groups received on a communications channel by effecting a comparison between the first-received and the second-received group.

27. The industrial process control system claimed in claim 22 further comprising:

memory means for storing the information groups received on one of said communication channels by said second-mentioned remote while the information groups received on the other communication channel is tested for validity.

28. A method for transferring digital information formatted in predetermined blocks between an information transmitting device and an interconnected information receiving device, said method comprising the steps of:

transmitting identical information blocks from a transmitter over plural independent communication channels to a receiver;

receiving and storing the received information blocks at the receiver;

selecting the information block received on one of said plural communication channels and testing the validity thereof;

selecting the information block received on the other of said communication channels and testing the validity thereof in the event the first-selected information block fails its validity check; and

requesting retransmission of said information blocks in the event both the first-selected and the second-selected information blocks fail their validity test.

29. The method claimed in claim 28 wherein said first-selection step further comprises the step of transmitting an acknowledgement signal from the receiver to the transmitter when the first-tested information block is found valid.

30. The method claimed in claim 29 wherein the second selection step further comprises the steps of transmitting an acknowledgement signal from the receiver to the transmitter when the second-tested information block is found valid.

31. The method claimed in claim 30 wherein the requesting step further comprises the step of transmitting a non-acknowledgement signal from the receiver to the transmitter when the second-tested information block is found invalid.

32. The method claimed in claim 31 further comprising the step of:

retransmitting the information blocks in response to a non-acknowledgement signal.

33. The method claimed in claim 32 further comprising the step of:

limiting the number of retransmissions to a predetermined value.

34. The method claimed in claim 29 wherein said transmitting step further comprises the step of transmitting identical information blocks on each channel at least twice in succession and the steps of testing the validity of an information block include a comparison between the first and second information blocks received on a channel.

35. In a control system of the type having a plurality of process control remotes interconnected through a communications link with each remote assigned a unique position in a predetermined succession order and each remote exercising supervisory control of the communication link on a revolving master basis, a method for transferring supervisory control of the communications link from a present system master to the next successive remote in the succession order comprising the steps of:

transmitting a control-transfer command signal along the communication link from the present system master to the next successive remote in the succession order;

receiving and evaluating the validity of the control-transfer command signal at the next successive remote;

sending an acknowledgement signal to the present system master from the next successive remote and accepting supervisory control of the communications link by the next successive remote from the present master if the control-transfer command signal is found valid by the next successive remote whereby the next successive remote becomes the present system master.

36. In a control system claimed in claim 35, said method further comprising the step of:

sending a non-acknowledgement signal from the next successive remote to the present system master if the evaluated control-transfer command signal if found invalid.

37. In a control system claimed in claim 36, said method further comprising the step of:

retransmitting the control-transfer command signal from the present master to said next successive remote in response to a non-acknowledgement signal from the next successive remote.

38. In a control system of the type having a plurality of process control remotes interconnected through a communications link with each remote assigned the unique position in a predetermined succession order and each remote exercising supervisory control of the communication link on a revolving master basis, each remote having a variable transfer monitor timer, a method for transferring supervisory control of the communication link from one remote to another comprising:

transmitting a control-transfer command signal along the communication link from the present system master to the next successive remote in the succession order;

setting, when said control-transfer command signal is transmitted from the present system master to the next successive master, the transfer-monitor time-out interval of at least the second successive remote from the present master to a time-out interval that is a function of a predetermined supervisory control transfer value and the position of the particular remote relative to the present master

said method operating in a normal mode comprising the further steps of;

(1) receiving and evaluating the validity of the control transfer command signal at the next successive remote;

(2) sending an acknowledgement signal to the present system master from the next successive remote; and

(3) accepting supervisory control of the communications link by the next successive remote from the present system master if the control transfer command signal is found valid by the next successive remote whereby the next successive remote becomes the present system master,

said method operating in an abnormal mode comprising the further step of accepting supervisory control of the communications link by the second successive remote from the present system master in the event the transfer-monitor timer of such second successive remote times out before the first successive remote accepts supervisory control in said normal mode of operation.

39. In a control system for controlling an industrial process of the type that includes a plurality of remote units each connected to an associated input/output device and interconnected through a communications link and in which each remote is assigned a unique position in a predetermined succession order, 0, 1, 2, 3, . . . m, . . . n, and each remote accepts supervisory control of the communications link on a master for the moment basis in accordance with the succession order, a method for transferring supervisory control of the communications link from a present system master R_m to the first successive remote R_m+1 comprising the steps of:

transmitting a control-transfer command signal through the communications link from the present system master R_m to the next successive remote R_m+1 ;

evaluating the validity of the control-transfer command signal at the next successive remote R_m+1 ;

sending an acknowledgement signal through the communications link from the next successive remote R_m+1 to the present system master R_m when the control-transfer command signal is found valid; and

accepting supervisory control of the communications link by the next successive remote R_m+1 from the present master R_m whereby the next successive remote R_m+1 becomes the present master R_m.

40. In a control system for controlling an industrial process of the type that includes a plurality of remote units each connected to an input/output device and interconnected through a common communications link and in which each remote is assigned a unique position in a predetermined succession order, 0, 1, 2, 3, . . . m, . . . n, and in which each remote accepts supervisory control of the communications link on a master for the moment basis and in which each remote includes a settable variable transfer-monitor timer, a method for sequentially transferring supervisory control of the communications link from the present master R_m to the next successive remote R_m+1 in the succession order and for transferring supervisory control of the communications link from the present system master R_m to the second successive remote R_m+2 in the event the next successive remote R_m+1 fails to accept supervisory control from the present system master R_m comprising the steps of:

transmitting a control-transfer command signal through the communications link from the present system master R_m to the next successive remote R_m+1 ;

setting the transfer-monitor timer of at least the second successive remote R_m+2 to a time-out interval based on a function of the successive remote'"'"'s position relative to the present system master R_m ;

said method in a normal mode of operation comprising the further steps of;

(1) evaluating the validity of the control-transfer command signal at the next successive remote R_m+1 ;

(2) sending an acknowledgement signal through the communications link from the next successive remote R_m+1 to the present system master R_m when the control-transfer command signal is found valid; and

(3) accepting syspervisory control of the communications link by the first successive R_m+1 from the present system master;

said method in an abnormal method of operation comprising the further step of;

accepting supervisory control of the communications link by the second successive remote R_m+2 when the transfer-monitor timer of the second successive remote R_m+2 times-out before the first successive remote R_m+1 accepts supervisory control of the communications link.

41. In a control system of the type having a plurality of process control remotes interconnected through a communications link with each remote assigned a unique position in a predetermined succession order and each remote exercising supervisory control of the communication link on a revolving master basis, a method for transferring supervisory control of the communications link from a present system master to the next successive remote in the succession order comprising the steps of:

transmitting a control-transfer command signal along the communication link from the present system master to the next successive remote in the succession order;

receiving and evaluating the validity of the control-system command signal at the next successive remote; and

accepting supervisory control of the communication link by the next successive remote from the present master if the control-transfer command signal is found valid by the next successive remote, whereby the next successive remote becomes the present system master.

42. A system for controlling an industrial process, said system comprising:

a plurality of process controlling remotes, a common communication link interconnecting said remotes, each remote being assigned a unique position in a predetermined succession order and each remote exercising supervisory control of the communication link on a master for a moment basis in accordance with the succession order;

each remote including a means for transmitting digital information in block format over said communications link to the other of the remotes and each including receiver means for receiving digital information transmitted from one other of the remotes; and

each remote including means for transferring the supervisory control to the next successive remote in the succession order by transmitting a control-transfer block over said communication link to the next successive remote in the succession order and the next successive remote accepting supervisory control of the communication link in response to said control-transfer block.

43. The system for controlling an industrial process claimed in claim 42, wherein:

each remote includes means for evaluating the validity of a received control-transfer block and for responding to a validly received control-transfer block by sending an acknowledgement signal to the transmitting remote to conclude the transfer of supervisory control.

44. The system for controlling an industrial process claimed in claim 43, wherein:

said evaluating means is operable to respond to an invalidly received control-transfer block by sending a non-acknowledgement signal to the transmitting remote.

45. The system for controlling an industrial process claimed in claim 44, wherein:

the transmitting remote in response to a non-acknowledgement signal to retransmit said control-transfer block.