Process control system using a control strategy implemented in a layered hierarchy of control modules

• US 5,862,052 A
• Filed: 04/12/1996
• Issued: 01/19/1999
• Est. Priority Date: 04/12/1996
• Status: Expired due to Term

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Lucas, Mike, Nixon, Mark, Beoughter, Ken J., Webb, Arthur, Havekost, Robert B., Jundt, Larry O., Stevenson, Dennis, Ott, Michael G.
• Primary Examiner(s): Kriess, Kevin A.
• Application Number:
  US08/631,520
• Time in Patent Office: 1,012 Days
• Field of Search: 395/651, 395/712, 395/704, 395/680, 395/683, 395/652, 395/653, 395/200.5, 395/200.51, 395/200.52, 364/468.15, 364/468.01, 364/468.24, 364/474.22, 364/551.01, 706/103
• US Class Current: 713/1
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 2219/23389 Modular program, each process has corresponding program module
• CPC Class Codes: G06F 11/2007 using redundant communication media
• CPC Class Codes: G06F 11/202 where processing functionality is redundant redundant communication control functionality G06F11/2005, redundant storage control functionality G06F11/2089
• CPC Class Codes: G06F 11/3048 where the topology of the computing system or computing system component explicitly influences the monitoring activity, e.g. serial, hierarchical systems
• CPC Class Codes: G06F 11/3065 Monitoring arrangements determined by the means or processing involved in reporting the monitored data error or fault reporting or logging G06F11/0766

Abstract

A process controller implements an overall, user-developed control strategy in a process control network that includes distributed controller and field devices. A user defines a module control strategy by specifying function blocks that make up control modules and determine the control strategy. The user modifies or debugs a module control strategy by adding, modifying and deleting function blocks, configuring parameters associated with the function blocks and creating a view to new attributes. By defining function blocks and control modules, a user-defined control strategy, application program or diagnostic program is represented as a set of layers of interconnected control objects identified as modules. A layer of the control strategy includes a set of modules which are interconnected in a user-specified manner. A module typically includes an algorithm for performing a specific function and display components which are used to display information to a user. A module is optionally represented to include a set of input and output connections for connecting to other modules. A module may be considered to be a "black box" which performs a specified function and is connected to other modules via specified input and output connections.

Claims

1. A control system for controlling a process comprising:

a controller coupled to the process; and

a software system executing on the controller and implementing a control strategy for controlling the process, the control strategy being defined by a layered hierarchy of modules in a configuration architecture including;

a process site layer;

one or more physical plant areas in a layer contained within the process site layer, the physical plant areas representing a geographical segmentation or logical segmentation of the process site layer;

one or more equipment modules contained within a physical plant area of the one or more physical plant areas, the equipment modules being associated to a specific object of plant equipment; and

one or more control modules contained within a physical plant area of the one or more physical plant areas or contained within an equipment module of the one or more equipment modules, the equipment modules and the control modules being elemental modules that contain exclusively one or more primitives, and composite modules that contain one or more elemental modules.

2. A control system according to claim 1 wherein:

the process includes a field device; and

an elemental module is an elemental function block defined in accordance with a Fieldbus standard protocol.

3. A control system according to claim 2 wherein:

the Fieldbus standard protocol is defined by an attribute set.

4. A control system according to claim 1 wherein:

the layered hierarchy of modules further includes a composite module that contains an elemental module and one or more primitives.

5. A control system according to claim 1 further comprising:

a user interface coupled to the controller for specifying the control strategy, the control strategy being user-specified by a module type of constituent elemental modules and composite modules, by interconnections between the constituent modules and by input/output connections of the constituent modules.

6. A control system according to claim 5 wherein:

the control strategy is user-modifiable by altering input/output connections of a constituent module.

7. A control system according to claim 5 wherein:

the control strategy is user-modifiable by extending input/output connections of a lower-level module to input/output connections of a higher level module.

8. A control system according to claim 5 wherein:

the user interface for modifying the control strategy is implemented in a plurality of process control programming languages.

9. A control system according to claim 1 wherein the software system further includes:

a configuration program for defining the control strategy and installing the control strategy on the controller, the controller retaining the configuration until reconfigured.

10. A control system according to claim 1 wherein the software system implements a control strategy that is scaled in size depending on the size of the process that is controlled.

11. A control system according to claim 1, wherein the control strategy is defined by downloading a control strategy module to the controller.

12. A control system according to claim 1, wherein the control strategy is defined by control strategy modules that are objects in an objectoriented environment.

40. A control system according to claim 1 wherein:

the configuration architecture is defined by a defined and specific set of users for visualizing system object relationships and locations, and for communicating or navigating among modules.

13. A process control system for controlling a plurality of field devices, the process control system comprising:

a plurality of distributed controllers coupled to the field devices for controlling a process; and

a distributed software system executing on the plurality of distributed controllers and implementing a control strategy for controlling the process, the control strategy being defined by a layered hierarchy of modules distributed for execution among the plurality of distributed controllers, the hierarchy of modules in a configuration architecture including;

a process site layer;

one or more physical plant areas in a layer contained within the process site layer, the physical plant areas representing a geographical segmentation or logical segmentation of the process site layer;

one or more equipment modules contained within a physical plant area of the one or more physical plant areas, the equipment modules being associated to a specific object of plant equipment; and

one or more control modules contained within a physical plant area of the one or more physical plant areas or contained within an equipment module of the one or more equipment modules, the equipment modules and the control modules being elemental modules that contain exclusively one or more primitives, and composite modules that contain one or more elemental modules.

14. A process control system according to claim 13 wherein:

an elemental module is an elemental function block defined in accordance with a Fieldbus standard protocol.

15. A process control system according to claim 14 wherein:

the Fieldbus standard protocol is defined by an attribute set.

16. A process control system according to claim 13 wherein:

the layered hierarchy of modules further includes a composite module that contains an elemental module and one or more primitives.

17. A process control system according to claim 13 further comprising:

a user interface coupled to the plurality of distributed controllers for specifying the control strategy, the control strategy being user-specified by distribution among controllers, by a module type of constituent elemental modules and composite modules, by interconnections between the constituent modules and by input/output connections of the constituent modules.

18. A process control system according to claim 17 wherein:

the control strategy is user-modifiable by altering input/output connections of a constituent module.

19. A process control system according to claim 17 wherein:

the control strategy is user-modifiable by extending input/output connections of a lower-level module to input/output connections of a higher level module.

20. A process control system according to claim 17 wherein:

the user interface for modifying the control strategy is implemented in a plurality of process control programming languages.

21. A process control system according to claim 13 wherein the distributed software system further includes:

a configuration program for defining the control strategy and installing the control strategy on the plurality of distributed controllers, the plurality of distributed controllers retaining the configuration until reconfigured.

22. A process control system according to claim 13 wherein the software system implements a control strategy that is scaled in size depending on the size of the process that is controlled.

23. A process control system according to claim 13, wherein the control strategy is defined by downloading a control strategy module to a selected controller of the plurality of distributed controllers.

24. A process control system according to claim 13, wherein the control strategy is defined by control strategy modules that are objects in an object-oriented environment.

41. A process control system according to claim 13 wherein:

the configuration architecture is defined by a defined and specific set of users for visualizing system object relationships and locations, and for communicating or navigating among modules.

25. A process control system comprising:

a plurality of field devices;

a plurality of distributed controllers coupled to the field devices for controlling a process; and

a distributed software system executing on the plurality of distributed controllers and implementing a control strategy for controlling the process, the control strategy being defined by a layered hierarchy of modules distributed for execution among the plurality of distributed controllers and the plurality of field devices, the hierarchy of modules in a configuration architecture including;

a process site layer;

one or more physical plant areas in a layer contained within the process site layers the physical plant areas representing a geographical segmentation or logical segmentation of the process site layer;

one or more equipment modules contained within a physical plant area of the one or more physical plant areas, the equipment modules being associated to a specific object of plant equipment; and

one or more control modules contained within a physical plant area of the one or more physical plant areas or contained within an equipment module of the one or more equipment modules, the equipment modules and the control modules being elemental modules containing exclusively one or more primitives and composite modules that contain exclusively one or more primitives, and composite modules that contain one or more elemental modules.

26. A process control system according to claim 25 wherein:

the plurality of field devices include smart-type field devices and non-smart-type field devices.

27. A process control system according to claim 25 wherein:

the plurality of field devices include Fieldbus-standard field devices and non-Fieldbus-standard field devices.

28. A process control system according to claim 25 wherein:

an elemental module is an elemental function block defined in accordance with a Fieldbus standard protocol.

29. A process control system according to claim 28 wherein:

the Fieldbus standard protocol is defined by an attribute set.

30. A process control system according to claim 25 wherein:

the layered hierarchy of modules further includes a composite module that contains an elemental module and one or more primitives.

31. A process control system according to claim 25 further comprising:

a user interface coupled to the plurality of distributed controllers for specifying the control strategy, the control strategy being user-specified by distribution among controllers, by a module type of constituent elemental modules and composite modules, by interconnections between the constituent modules and by input/output connections of the constituent modules.

32. A process control system according to claim 31 wherein:

the control strategy is user-modifiable by altering input/output connections of a constituent module.

33. A process control system according to claim 31 wherein:

the control strategy is user-modifiable by extending input/output connections of a lower-level module to input/output connections of a higher level module.

34. A process control system according to claim 31 wherein:

the user interface for modifying the control strategy is implemented in a plurality of process control programming languages.

35. A process control system according to claim 25 wherein the distributed software system further includes:

a configuration program for defining the control strategy and installing the control strategy on the plurality of distributed controllers, the plurality of distributed controllers retaining the configuration until reconfigured.

36. A process control system according to claim 25 wherein the software system implements a control strategy that is scaled in size depending on the size of the process that is controlled.

42. A process control system according to claim 25 wherein:

the configuration architecture is defined by a defined and specific set of users for visualizing system object relationships and locations, and for communicating or navigating among modules.

37. A control system for controlling a process under direction of a user, the control system comprising:

a controller coupled to the process; and

a software system executing on the controller and implementing a control strategy for controlling the process, the control strategy being defined by an hierarchy of layers including;

a site layer;

a plurality of physical plant areas allocated within the site layer;

a plurality of equipment modules allocated within the plurality of physical plant areas, the equipment modules including composite equipment modules that contain other equipment modules; and

a plurality of control modules allocated within a plant area of the plurality of physical plant areas or within an equipment module of the plurality of equipment modules, the control modules being objects of a container class, a control module of the plurality of control modules having a specified task and a predefined external interface, the control module being encapsulated in the software system and accessed through the predefined external interfaces so that the control module is user-modifiable.

38. A control system according to claim 37, wherein the specified task of the control module is user-modifiable.

39. A control system according to claim 37, wherein the predefined external interfaces a re user-modifiable.