Distributed environmental process control system

• US 5,831,848 A
• Filed: 11/17/1995
• Issued: 11/03/1998
• Est. Priority Date: 11/17/1995
• Status: Expired due to Term

• Current Assignee: Phoenix Controls Corporation (Honeywell International Inc.)
• Original Assignee: Phoenix Controls Corporation (Honeywell International Inc.)
• Inventors: Labrecque, Robert, Vincent, Maurice R., Fortier, Joseph W., Rielly, David A., Desrochers, Eric M.
• Primary Examiner(s): Elmore, Reba I.
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US08/559,822
• Time in Patent Office: 1,082 Days
• Field of Search: 364/131, 364/132, 364/135-140, 364/550, 364/557, 364/140.01-140.05, 395/200.1, 395/200.19, 395/200.05, 395/553, 395/559, 395/651, 395/200.3, 395/200.55, 395/200.78, 395/200.68, 395/200.73, 395/200.38, 370/401, 370/402, 370/502, 370/458, 370/443, 370/459, 454/61, 454/238, 454/59, 454/56, 454/234, 236/49.3, 236/49.4, 236/51
• US Class Current: 700/3
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/2638 Airconditioning
• CPC Class Codes: G05B 2219/31188 Combine csma-cd and tdm time multiplexed for rapid status exchange
• CPC Class Codes: G05B 2219/33144 Module clock, synchronised by controller message, to send message in time slice
• CPC Class Codes: G05B 2219/33187 Serial transmission rs232c, rs422, rs485 communication link
• CPC Class Codes: G05B 2219/33248 Time window for each controller or controlled function
• CPC Class Codes: G05B 2219/33251 Schedule periodic and aperiodic traffic, real time, time critical
• CPC Class Codes: G05B 2219/33252 Real time synchronous transmission, model
• CPC Class Codes: G05B 2219/50102 Store history of operation, after power failure, restart from history, journal
• CPC Class Codes: H04L 12/403 with centralised control, e.g. polling
• CPC Class Codes: H04L 2012/4026 Bus for use in automation systems
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A process control system includes a high speed serial backbone communications network, interconnecting a plurality of microprocessor based nodes that each act as the master to a high speed serial branch network comprising device controllers, such as air flow valve controllers and transducers. The primary network may operate in a time division multiplex mode whereby a node acting as a synchronizing station periodically issues a synchronizing signal that commands each node to execute a branch network control sequence, during which each node gathers and operates upon data it collects from the device controllers within its branch network, and issues commands based thereon to the branch network. An ensuing communications sequence also triggered by the synchronizing signal enables each node on the primary network to transmit a command or a response to any other node and, through such other node, to any device controller in any branch network of the system. Serial ports on each node permit user access from any node on the primary network to any other point on the system for purposes of monitoring and control. Serial ports on each device controller permit user access to local device parameters.

Claims

1. A computer network for real-time control of an indoor environment, the computer network comprising:

a plurality of controller units each controller unit having a first network interface and a second network interface, one controller further having a serial port through which external commands are received; and

a plurality of environmental control devices connected to the first network interface of a predetermined controller unit, the predetermined controller unit communicating through the first network interface with the plurality of environmental control devices using a first synchronous communications protocol;

wherein the second network interfaces of the plurality of controller units are connected to each other, the plurality of controller units communicating with each other through the second network interfaces using a second synchronous communications protocol in which one time slot is reserved for the communicating through the first network interface by the predetermined controller unit to which the plurality of environmental control devices are connected; and

further

wherein communicating through the second network interface is inhibited during the reserved time slot.

2. The computer network of claim 1, wherein the first synchronous communications protocol and the second synchronous communications protocol each are synchronous data link control protocols.

3. The computer network of claim 2, wherein the second synchronous communications protocol further includes a plurality of time slots corresponding to the plurality of controllers for exclusive use thereby.

4. The computer network of claim 2, wherein the first synchronous communications protocol further includes:

a plurality of time slots corresponding to the plurality of environmental control devices for exclusive use thereby;

a time period of no communication, during which the predetermined controller unit solves an environmental control equation; and

a time period during which the controller broadcasts a solution of the environmental control equation over the first network interface.

5. The computer network of claim 1, wherein at least one of the first synchronous communications protocol and the second synchronous communications protocol operate over a shielded twisted-pair cable medium.

6. The computer network of claim 1, wherein the plurality of environmental control devices include air flow transducers, air supply devices and air exhaust devices, further comprising:

software executing in the predetermined controller unit to which the plurality of environmental control devices are connected, the software including instructions for measuring air flow using the air flow transducers and adjusting set points of the air supply devices and the air exhaust devices to achieve a desired air flow and pressure.

7. The computer network of claim 1, wherein the one controller and the predetermined controller unit are the same controller unit of the plurality of controller units.

8. A method of communicating in a computer network including a backbone network of nodes, each node also controlling a branch network, comprising the steps of:

multiplexing communications between nodes using a synchronous peer-to-peer communications protocol,

reserving at least one time slot during which no communications occur between nodes;

during the reserved time slot, performing independent communications between each node and its branch network using a synchronous communications protocol.

9. The method of claim 8, wherein one node generates synchronization signals, the method further comprising the steps of:

the synchronization signals failing to reach a first node after a first predetermined time period; and

the first node generating a replacement synchronization signal after the predetermined time period.

10. The method of claim 9, further comprising the steps of:

the synchronization signals and the replacement synchronization signal failing to reach a second node after a second predetermined time period longer than the first predetermined time period; and

the second node generating a new replacement synchronization signal after the second predetermined time period.

11. The method of claim 8, wherein a plurality of devices reside on the branch network, and wherein a synchronization signal is generated by the nodes, and

said synchronization signal generates a deterministic response by the devices residing on the branch network, simultaneously at each node.

12. The method of claim 11 wherein said response comprises the communication of at least three items of control information per device controller, and

said node controlling a branch network maintains a summed tally of at least one such item of control information as each device controller responds.

13. The method of claim 12 wherein at the completion of all device controller responses the branch controller issues a single transmission comprising data algebraically compiled based on said tally of said items of control information, and

said data from said single transmission is selectively receivable by less than all of the device controllers.

14. The method of claim 12, wherein the summed tally is a sum of air flow rates in a building environmental control system.

15. The method of claim 14, further comprising the step of:

said branch controller issuing a single transmission comprising air flow rate set point data computed from the summed tally.

16. The method of claim 15, further comprising the step of:

less than all of the device controllers receiving the data contained in the single transmission.

17. The method of claim 11 wherein communication of lesser defined information may also take place on the branch network prior to the commencement of communications between nodes.

18. The method of claim 8, further comprising the step of:

transmitting a message between a node and an environmental control device through the node'"'"'s branch network.

19. The method of claim 18, wherein the step of transmitting further comprises the step of:

giving the environmental control device an operating set point.

20. The method of claim 19, further comprising the step of:

receiving from the environmental control device a measurement of operating conditions.

21. The method of claim 20, further comprising the step of:

computing a new value for the operating set point, the new value based on the measurement of operating conditions.

22. In a computer network for real-time control of environmental control devices, the computer network including

a plurality of nodes, each node connected for communication through a backbone network using time division multiplexing;

a branch network, connected to a corresponding node; and

a plurality of environmental controls connected to the branch network for communication with corresponding node;

the improvement comprising;

the time division multiplexing by which the plurality of nodes communicate includes at least one time slot during which no communications occur between nodes; and

the plurality of environmental controls communicate through the branch network with the corresponding node during the at least one time slot.

23. The computer network of claim 22 wherein the backbone network includes a shielded twisted-pair cable medium.

24. The computer network of claim 22, wherein communication over the backbone network is performed using a synchronous peer-to-peer protocol.

25. The computer network of claim 22, wherein:

one of the nodes generates a synchronization signal and the synchronization signal triggers deterministic responses by the plurality of environmental controls.

26. The computer network of claim 25, wherein communication of lesser defined information may also take place on a branch network.

27. In a computer network for real-time control of environmental control devices, the computer network including

a plurality of nodes, each node connected for communication through a backbone network using time division multiplexing;

a branch network, connected to a corresponding node; and

a plurality of environmental controls connected to the branch network for communication with corresponding node;

the improvement comprising;

the time division multiplexing by which the plurality of nodes communicate includes at least one time slot during which no communications occur between nodes; and

the plurality of environmental controls communicate through the branch network with the corresponding node during the at least one time slot, wherein communication over the backbone network is performed using a synchronous peer-to-peer protocol, further comprising a synchronizing node having an output carrying a synchronization signal, the output connected to the backbone network,

a first one of the plurality of nodes having an output carrying a replacement synchronization signal when the synchronization signal fails to reach the first node within a predetermined period of time.

28. The computer network of claim 27, wherein:

a second one of the plurality of nodes having an output carrying a new replacement synchronization signal when the synchronization signal and the replacement synchronization signal both fail to reach the second node within a second predetermined period of time.

29. In a computer network for real-time control of environmental control devices, the computer network including

a plurality of nodes, each node connected for communication through a backbone network using time division multiplexing;

a branch network, connected to a corresponding node; and

a plurality of environmental controls connected to the branch network for communication with corresponding node;

the improvement comprising;

the time division multiplexing by which the plurality of nodes communicate includes at least one time slot during which no communications occur between nodes; and

the plurality of environmental controls communicate through the branch network with the corresponding node during the at least one time slot, wherein;

one of the nodes generates a synchronization signal and the synchronization signal triggers deterministic responses by the plurality of environmental controls, wherein said deterministic responses include a plurality of control data for each environmental control and wherein the one of the nodes maintains a summed tally of at least one of the control data.

30. The computer network of claim 29, wherein the node generates a single transmission selectively receivable by less than all of the environmental controls, the transmission comprising data algebraically compiled based on the tally.