Output weighted partitioning method for a control program in a highly distributed control system

• US 5,896,289 A
• Filed: 09/05/1996
• Issued: 04/20/1999
• Est. Priority Date: 09/05/1996
• Status: Expired due to Term

• Current Assignee: Allen-Bradley Company (Rockwell Automation, Inc.)
• Original Assignee: Allen-Bradley Company LLC (Rockwell Automation, Inc.)
• Inventors: Struger, Odo J.
• Primary Examiner(s): Elmore, Reba I.
• Assistant Examiner(s): PATEL, RAMESH B
• Application Number:
  US08/711,378
• Time in Patent Office: 957 Days
• Field of Search: 364/138, 364/146, 364/147, 364/185, 364/188-192, 364/131-136, 364/159, 364/578, 364/488, 364/491, 395/82, 395/84, 395/158, 395/155, 395/159, 395/161, 395/500, 455/445, 455/456, 455/457, 455/8, 455/9
• US Class Current: 700/9
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/1204 Multiprocessing, several plc's, distributed logic control
• CPC Class Codes: G05B 2219/1207 Download programcode to node, I-O and execute programcode
• CPC Class Codes: G05B 2219/13068 Program divided in operation blocks, groups, tasks each executed
• CPC Class Codes: G05B 2219/13125 Use of virtual, logical connections
• CPC Class Codes: G05B 2219/23463 Before controlling module execute monitoring of module and its resources

Abstract

A method of partitioning a control program among many spatially separated computing devices places most of the program instructions in computing devices supporting outputs to the controlled processor equipment. Inputs then simply report their data to the output computing devices rather than having that data processed by a path of computing devices communicating with each other such as may cause the evaluation of the outputs to be delayed by multiple transmissions on the common link.

Claims

1. A partitioning program for dividing a control program, used to control industrial equipment, into portions to be executed by spatially separated computing devices;

where the computing devices have a program memory and communicate with other computing devices via messages on a communications link and are attached to parts of the industrial equipment directly, not through the communications link, to provide output signals and to receive input signals;

where the control program, when executed, accepts the input signals from the industrial equipment and determines the output signals to the industrial equipment and input instructions testing input signals to the industrial equipment;

where the control program is composed of logically interconnected program instructions including output instructions representing output signals to the industrial equipment;

the partitioning program executing on an electronic computer and comprising;

(a) an allocation routine reviewing the control program to identify output instructions and copying a given output instructions from the control program to the program memory of a particular computing device that is directly attached to the part of the industrial equipment receiving the output signal of the given output instruction; and

(b) a collection routine identifying other program instructions including input instructions on which the output signal represented by the given output instruction depends, and based on that identification, copying into the program memory of the particular computing device, the other program instructions on which the output signal represented by the given output instructions depends.

2. The partitioning program recited in claim 1 including in addition:

(c) a linking routine copying to computing devices receiving input signals needed by the other program instructions, a connection record indicating a path of communication on the communication link to the particular computing device holding the given output instruction.

3. The partitioning program recited in claim 1 including in addition:

(c) a linking routine copying to the particular computing device addresses on the communication link of other computing devices receiving input signals needed by the other program instructions.

4. The partitioning program recited in claim 1 wherein the control program is written using relay ladder instructions and the output instructions are coil instructions.

5. The partitioning program recited in claim 1 wherein the control program is written using relay ladder instructions and the other instructions include contact instructions.

6. A highly distributed industrial control system executing a control program composed of logically interconnected program instructions including output instructions representing output signals to industrial equipment, the highly distributed industrial control system comprising:

(1) a communication link;

(2) a plurality of computing devices having program memories and programmed to communicate with other computing devices via messages on a communications link;

(a) the computing devices including at least a first and second output computing device directly attached to a first and second part of the industrial equipment, not through the communications link, to provide output signals to the parts of the industrial equipment;

(i) the program memory of the first output computing device holding;

(A) at least one first output instruction from the control program representing a first output signal to the first part of the industrial equipment directly attached to the first output computing device;

(B) other program instructions on which the first output signal represented by the first output instruction depends;

(ii) the program memory of the second output computing device holding;

(A) at least one second output instruction from the control program representing a second output signal to the second part of the industrial equipment directly attached to the second output computing device;

(B) other program instructions on which the second output signal represented by the second output instruction including redundant program instructions also held in the program memory of the first output computing device;

(b) the computing devices also depends including input computing devices directly attached to parts of the industrial equipment not through the communications link to receive input signals, the input computing device programmed to relay input signals from the parts of the industrial equipment to the output computing devices having program instructions requiring the input signals.

7. The highly distributed industrial control system recited in claim 6 wherein the input computing devices are programmed to broadcast input signals to all computing devices on the link.

8. The highly distributed industrial control system recited in claim 6

wherein the output computing devices are programmed to poll the input computing devices for other instructions on which the output instruction of the output computing device depends, and

wherein the input computing devices are programmed to respond to polling messages of the output computing devices in relaying the input signals.

9. The partitioning program recited in claim 6 wherein the control program is written using relay ladder instructions and the output instructions are coil instructions.

10. The partitioning program recited in claim 6 wherein the control program is written using relay ladder instructions and the other instructions include contact instructions.