Process control system for monitoring and displaying diagnostic information of multiple distributed devices

• US 5,995,916 A
• Filed: 04/12/1996
• Issued: 11/30/1999
• 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: Ottenbacher, Ron, Nixon, Mark, Havekost, Robert B., Jundt, Larry O.
• Primary Examiner(s): SHAH, KAMINI S
• Application Number:
  US08/631,557
• Time in Patent Office: 1,327 Days
• Field of Search: 395/295, 395/200.14, 395/200.09, 395/182.09, 364/551.01, 364/131, 364/188, 364/473, 235/150.01, 702/182
• US Class Current: 702/182
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 23/0208 characterized by the configuration of the monitoring system
• CPC Class Codes: G06F 11/321 Display for diagnostics, e.g. diagnostic result display, self-test user interface

Abstract

A process control system includes a diagnostic monitoring and display functionality for viewing, in a coherent manner, diagnostic information relating to a process that operates over multiple devices and system components. Although the multiple devices and system components typically encompass widely different device types and operational standards, the process control system incorporates diagnostic information relating to all devices and presents this information to a system user in a uniform manner so that an operating control strategy and the diagnostic information are presented as though all control actions and diagnostic information were performed or generated at a single location. A user-defined diagnostic program is assembled as a set of function blocks and control modules and represented as a set of layers of interconnected control objects identified as modules which include informational structures accessed as attributes. Information is accessed using device hierarchy attribute addressing, supporting direct addressing of I/O signals from modules, bypassing the use of I/O function blocks and avoiding I/O function block behavior.

Claims

1. A process control system comprising:

a field device including a source of diagnostic information;

a controller coupled to the field device;

a workstation coupled to the controller and including a user interface; and

a software system implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively defining and creating the diagnostic modules and event attributes defining the diagnostic information of the diagnostic modules, and for user-selectively distributing the diagnostic modules among the field device, the controller, and the workstation;

a plurality of diagnostic modules selectively defined and created via the user interface using the configuration routine for access using the diagnostic monitoring and display program, the diagnostic modules operating mutually independently and in parallel accessing the source of diagnostic information; and

a display routine for accessing diagnostic information from the plurality of diagnostic modules and displaying the diagnostic information accessed from the plurality of diagnostic modules uniformly for all diagnostic modules in the process control system so that the diagnostic information relating to a process that operates both in the controller and in the field device is displayed in the same manner regardless of the source of the diagnostic information.

2. A process control system according to claim 1, wherein:

the plurality of diagnostic modules are selectively defined and created, and selectively distributed by a user.

3. A process control system according to claim 1, wherein:

the field device includes a control element; and

a diagnostic module of the plurality of diagnostic modules is distributed to the field device and monitors a condition or status of the control element.

4. A process control system according to claim 1 wherein

the field device is a Fieldbus standard device including a control element;

and

a diagnostic module of the plurality of diagnostic modules is distributed to the control element and accesses Fieldbus standard diagnostic information indicative of a condition or status of the control element.

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

a plurality of field devices including a Fieldbus standard field device and a non-Fieldbus standard device.

6. A process control system according to claim 1, further comprising:

a storage for storing device information including configuration information and status information relating to the field device;

wherein

the display routine further accesses, in addition to the diagnostic information, the configuration and status information from the storage and displays the configuration information, status information and diagnostic information.

7. A process control system according to claim 6 wherein the storage is a common storage for device information in the process control system for single access updating and maintenance.

8. A process control system according to claim 7, further comprising:

a network coupled to the controller; and

an external node coupled to the controller through the network so that device information including real-time data, history information, event statistics, configuration data and diagnostic information are accessed using network standard communications.

9. A process control system according to claim 1, further comprising:

a network coupled to the controller; and

a remote display coupled to the controller through the network so that the diagnostic information is accessed by the remote display.

10. A process control system according to claim 1, further comprising:

a network coupled to the controller including a plurality of separate communications links for carrying network traffic and traffic directed among the field device, the controller and the workstation.

11. A process control system comprising:

a field device including a source of diagnostic information;

a controller coupled to the field device;

a workstation coupled to the controller and including a user interface; and

a software system implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively and interactively;

defining and creating new types of control modules and diagnostic modules and modifying previously existing types of control modules and diagnostic modules;

defining and setting control module attributes, the control modules and control attributes specifying a control strategy;

defining and setting diagnostic module attributes; and

selectively distributing the control modules and the diagnostic modules among the field device, the controller, and the workstation;

a plurality of control modules for selectively implementing a process control strategy,

a plurality of diagnostic modules selectively defined and created via the user interface using the configuration routine for access using the diagnostic monitoring and display program, the diagnostic modules operating mutually independently and in parallel accessing the source of diagnostic information; and

a display routine for accessing diagnostic information from the plurality of diagnostic modules and a control scheme from the plurality of control modules and for respectively displaying the diagnostic information accessed from the plurality of diagnostic modules and the control strategy accessed from the plurality of control modules so that the diagnostic information and the control information are accessed in the same manner.

12. A process control system according to claim 11 wherein the diagnostic information accessed from the plurality of diagnostic modules and the control scheme accessed from the control modules are accessed and displayed in a uniform manner.

13. A process control system according to claim 11 wherein a diagnostic module is a primitive module.

14. A process control system comprising:

a plurality of field devices, a field device of the plurality of field devices including a source of diagnostic information;

a plurality of controllers, a controller of the plurality of controllers being coupled to a field device of the plurality of field devices;

a workstation coupled to the controller and including a user interface; and

a software system implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively and interactively;

defining and creating new types of diagnostic modules and modifying previously existing types of diagnostic modules;

defining and setting diagnostic module attributes; and

selectively distributing the diagnostic modules among the field device, the controller, and the workstation;

a plurality of diagnostic modules selectively defined and created via the user interface using the configuration routine for access using the diagnostic monitoring and display program, the diagnostic modules operating mutually independently and in parallel; and

a display routine for accessing diagnostic information from the plurality of diagnostic modules operating mutually independently on the field devices, the controllers and the workstation and displaying the diagnostic information accessed from the plurality of diagnostic modules uniformly so that the diagnostic information relating to a process that operates more than one of the field devices, the controllers and the workstation is displayed as being generated at a single location.

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

the plurality of diagnostic modules are selectively defined and created and selectively distributed by a user.

16. A process control system according to claim 14, wherein:

a field device of the plurality of field devices includes a control element; and

a diagnostic module of the plurality of diagnostic modules is distributed to the field device and monitors a condition or status of the control element.

17. A process control system according to claim 14, further comprising:

a storage for storing device information including configuration information and status information relating to the field device;

wherein

the display routine further accesses, in addition to the diagnostic information, the configuration and status information from the storage and displays the configuration information, status information and diagnostic information.

18. A process control system according to claim 17 wherein the storage is a common storage for device information in the process control system for single access updating and maintenance.

19. A process control system according to claim 18, further comprising:

a network coupled to the controller; and

an external node coupled to the controller through the network so that device information including real-time data, history information, event statistics, configuration data and diagnostic information are accessed using network standard communications.

20. A process control system according to claim 14, further comprising:

a network coupled to the controller; and

a remote display coupled to the controller through the network so that the diagnostic information is accessed by the remote display.

21. A process control system according to claim 14, further comprising:

a network coupled to the controller including a plurality of separate communications links for carrying network traffic and traffic directed among the plurality of field devices, the plurality of controllers, and the workstation.

22. A process control system comprising:

a plurality of field devices, a field device of the plurality of field devices including a source of diagnostic information;

a plurality of control means for controlling a field device, a control means of the plurality of control means being coupled to a field device of the plurality of field devices;

an interface means coupled to the plurality of control means for interfacing the control process system to a user;

a configuration means for user-selectively and interactively;

defining and creating new types of diagnostic means and modifying previously existing types of diagnostic means;

defining and setting diagnostic means attributes; and

selectively distributing the diagnostic means among the field device, the controller, and the workstation;

a diagnostic means for implementing a process control strategy, the diagnostic means being selectively defined and created as a plurality of diagnostic modules, the plurality of diagnostic modules upon creation being selectively distributed among the field device, control means and interface means, the diagnostic modules operating mutually independently and in parallel; and

a display means for accessing diagnostic information from the plurality of diagnostic means operating mutually independently on the field devices, the controllers and the workstation and displaying the diagnostic information accessed from the plurality of diagnostic modules uniformly so that the diagnostic information relating to a process that operates more than one of the field devices, the controllers and the workstation is displayed as being generated at a single location.

23. A process control system according to claim 22, wherein:

the diagnostic means is selectively defined and created as diagnostic modules and selectively distributed among the plurality of field devices, the plurality of control means and the interface means by a user.

24. A process control system according to claim 22, wherein:

a field device of the plurality of field devices includes a field device control means for controlling field device operations; and

the diagnostic means includes a diagnostic module that is distributed to and operational upon the field device control means.

25. A process control system according to claim 22 wherein

a field device of the plurality of field devices is a Fieldbus standard device including a field device diagnostic means for accessing Fieldbus diagnostic operations;

and

a diagnostic module is distributed to the field device control means and operates as a Fieldbus standard function block.

26. A process control system according to claim 22 wherein

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

27. A process control system according to claim 22, further comprising:

a storage for storing device information including configuration information and status information relating to the field device;

wherein

the display routine further accesses, in addition to the diagnostic information, the configuration and status information from the storage and displays the configuration information, status information and diagnostic information.

28. A process control system according to claim 27 wherein the storage is a common storage for device information in the process control system for single access updating and maintenance.

29. A process control system according to claim 22, further comprising:

a remote display coupled to the controller so that the diagnostic information is accessed by the remote display.

30. A process control system comprising:

a field device including a source of diagnostic information;

a controller coupled to the field device;

a workstation coupled to the controller and including a user interface; and

a software system implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively and interactively;

defining and creating new types of control strategy modules and modifying previously existing types of control strategy modules;

defining and setting control module attributes, the control strategy modules and control module attributes specifying the control strategy; and

distributing the control strategy modules among the field device, the controller, and the workstation;

a control strategy for the process control system, the control strategy being selectively apportioned into a plurality of control strategy modules and selectively distributed among the field device, controller and workstation, the control strategy modules operating mutually independently and in parallel;

a plurality of diagnostic modules selectively defined and created via the user interface for access using the diagnostic monitoring and display program, the plurality of diagnostic modules upon creation being selectively distributed among the field device, the controller and the workstation, the diagnostic modules operating mutually independently and in parallel accessing the source of diagnostic information; and

a display routine for accessing diagnostic information from the plurality of diagnostic modules and displaying the control strategy and the diagnostic information accessed from the plurality of diagnostic modules uniformly so that the diagnostic information relating to a process that operates both in the controller and in the field device is displayed as being generated at a single location.

31. A process control system according to claim 30, wherein:

the plurality of control strategy modules and diagnostic modules are selectively defined and created, and selectively distributed by a user.

32. A process control system according to claim 30, wherein:

the field device includes a control element;

a diagnostic module of the plurality of diagnostic modules is distributed to the field device; and

a control strategy of the plurality of control strategies is selectively defined and created, and selectively distributed by a user.

33. A process control system according to claim 30 wherein

the field device is a Fieldbus standard device including a control element;

a diagnostic module of the plurality of diagnostic modules is distributed to the control element and accesses Fieldbus standard diagnostic information to monitor a condition or status of the control element; and

a control strategy module is distributed to the control element and operates as a Fieldbus standard function block.

34. A process control system according to claim 30, further comprising:

a plurality of field devices including a Fieldbus standard field device and a non-Fieldbus standard device.

35. A process control system according to claim 30, further comprising:

a storage for storing device information including configuration information and status information relating to the field device;

wherein

the display routine further accesses, in addition to the diagnostic information, the configuration and status information from the storage and displays the configuration information, status information and diagnostic information.

36. A process control system according to claim 35 wherein the storage is a common storage for device information in the process control system for single access updating and maintenance.

37. A computer program product comprising:

a computer usable medium having computable readable code embodied therein for controlling a process control system including a source of diagnostic information, a controller coupled to a field device, and a workstation coupled to the controller and including a user interface, the executing program code implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively and interactively;

defining and creating new types of diagnostic modules and modifying previously existing types of diagnostic modules;

defining and setting diagnostic module attributes; and

selectively distributing the diagnostic modules among the field device, the controller and the workstation;

a plurality of diagnostic modules selectively defined and created via the user interface using the configuration routine for access using the diagnostic monitoring and display program, and

a display routine for accessing diagnostic information from the plurality of diagnostic modules and displaying the diagnostic information accessed from the plurality of diagnostic modules uniformly for all diagnostic modules in the process control system so that the diagnostic information relating to a process that operates both in the controller and in the field device is displayed in the same manner regardless of the source of the diagnostic information.

38. An article of manufacture storing the computer program product according to claim 37.

39. A computer program product comprising:

a computer usable medium having computable readable code embodied therein for controlling a process control system including a field device having a source of diagnostic information, a controller coupled to the field device, a workstation coupled to the controller, and a user interface, the executable program code implementing a diagnostic monitoring and display program for the process control system, the diagnostic monitoring and display program including;

a configuration routine for user-selectively and interactively;

defining and creating new types of control modules and diagnostic modules and modifying previously existing types of control modules and diagnostic modules;

defining and setting control module attributes, the control modules and control attributes specifying a control strategy;

defining and setting diagnostic module attributes; and

selectively distributing the control modules and the diagnostic modules among the field device, the controller, and the workstation;

a plurality of control modules for selectively implementing a process control strategy;

a plurality of diagnostic modules selectively defined and created via the user interface for access using the diagnostic monitoring and display program, the diagnostic modules operating mutually independently and in parallel accessing the source of diagnostic information; and

a display routine for accessing diagnostic information from the plurality of diagnostic modules and a control scheme from the plurality of control modules and for respectively displaying the diagnostic information accessed from the plurality of diagnostic modules and the control strategy accessed from the plurality of control modules so that the diagnostic information and the control information are accessed in the same manner.

40. An article of manufacture storing the computer program product according to claim 39.