Process control system for versatile control of multiple process devices of various device types

• US 6,032,208 A
• Filed: 04/12/1996
• Issued: 02/29/2000
• 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: Hoffmaster, James, Nixon, Mark, Webb, Arthur, Lucas, Mike, Havekost, Robert B., Jundt, Larry O., Stevenson, Dennis, Ott, Michael G.
• Primary Examiner(s): Oberley, Alvin E.
• Assistant Examiner(s): COURTENAY III, ST JOHN
• Application Number:
  US08/631,521
• Time in Patent Office: 1,418 Days
• Field of Search: 395/651, 395/712, 395/704, 395/680, 395/828-839, 710/8, 710/62, 710/63, 710/64, 364/130
• US Class Current: 710/64
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• 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 controller implements smart field device standards and other bus-based architecture standards so that communications and control among devices are performed so that the standard control operations are transparent to a user. The process controller allows attachment to a theoretically and substantially unlimited number and type of field devices including smart devices and conventional non-smart devices. Control and communication operations of the various numbers and types of devices are performed simultaneously and in parallel.

Claims

1. A process control system for controlling a plurality of field devices of multiple different field device types including smart-type field devices and non-smart-type field devices, the process control system comprising:

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

a software system including a plurality of control modules that are selectively defined and created at configuration by a user to define and create a control strategy, and installed on ones of the plurality of distributed controllers, the control modules including control modules executable in the distributed controllers and control modules executable in processing units in the smart-type field devices, the smart-type field devices being controlled by control modules executable independently and in parallel in the distributed controllers and in the smart-type field device processing units, and the non-smart-type field devices being controlled by control modules executable in the distributed controllers, the control modules controlling the smart-type and the non-smart-type field devices to implement smart-type field device standards on both the smart-type field devices and non-smart-type field devices so that standard control operation is transparent to a user.

2. A process control system according to claim 1, wherein the smart-type field devices include Fieldbus standard field devices.

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

a user interface for interfacing with a user;

wherein

the smart-type and the non-smart-type field devices operate in compliance with defined bus-based architecture standards and the software system performs smart-type control operations and non-smart-type control operations transparent to the user over the user interface.

4. A process control system according to claim 1, wherein the software system performs smart-type control operations using the plurality of control modules distributed on the plurality of distributed controllers operating on the smart-type field devices and non-smart-type operations operating on the non-smart-type field devices independently, simultaneously and in parallel.

5. A process control system according to claim 1 wherein ones of the distributed controllers perform different control operations.

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

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

7. A process control system according to claim 1, wherein the control modules are selectively installable by downloading a selected control module to a controller of the plurality of distributed controllers.

8. A process control system according to claim 1, wherein the control modules are objects in an object-oriented environment.

9. A process control system according to claim 1 wherein the plurality of control modules is configured into a communication services hierarchy including:

a remote object communications (ROC) level for communicating messages between two control modules in a same controller and between two control modules in different controllers, and

a low level communications level for interfacing with communications hardware and transmitting messages across the communications hardware.

10. A process control system according to claim 1, wherein the control modules include a device connection object for controlling data transfers between a plurality of devices, transmitting data, maintaining communication link status between two communicating devices and establishing a communication link upon demand of a remote device.

36. A process control system according to claim 1 wherein the software system communicates with the smart-type and the non-smart-type field devices via network server/client pairs.

11. A process control system for controlling a plurality of field devices of multiple different field device types including smart-type field devices and non-smart-type field devices, the process control system comprising:

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

a plurality of control means that are selectively defined and created at configuration by a user to define and create a control strategy, and installed on ones of the plurality of distributed controllers, the the plurality of control means including control means executable in the distributed controllers and control means executable in processing units in the smart-type field devices the smart-type field devices being controlled by control means executable independently and in parallel in the distributed controllers and in the smart-type field device processing units and the non-smart-type field devices being controlled by control means executable in the distributed controllers the control means controlling the smart-type field devices and the non-smart-type field devices to implement smart-type field device standards on both the smart-type field devices and non-smart-type field devices so that standard control operation is transparent to a user.

12. A process control system according to claim 11, wherein the smart-type field devices include Fieldbus standard field devices.

13. A process control system according to claim 11, further comprising:

means for interfacing with a user;

wherein

the smart-type and the non-smart-type field devices operate in compliance with defined bus-based architecture standards and the plurality of control means perform smart-type control operations and non-smart-type control operations transparent to the user over the interfacing means.

14. A process control system according to claim 11, wherein the plurality of control means distributed on the plurality of distributed controllers perform smart-type control operations operating on the smart-type field devices and non-smart-type operations operating on the non-smart-type field devices independently, simultaneously and in parallel.

15. A process control system according to claim 11 wherein ones of the control means perform different control operations.

16. A process control system according to claim 11 wherein the control means further includes:

configuring means for configuring the control modules and installing the control modules on the plurality of distributed controllers, the distributed controllers retaining the configuration until reconfigured.

17. A process control system according to claim 11, wherein the control means are selectively installable by downloading a selected control means to a controller of the plurality of distributed controllers.

18. A process control system according to claim 11, wherein the control means are objects in an object-oriented environment.

19. A process control system according to claim 11, wherein the control means include a device connection object for controlling data transfers between a plurality of devices, transmitting data, maintaining communication link status between two communicating devices and establishing a communication link upon demand of a remote device.

37. A process control system according to claim 11 wherein the plurality of control means communicate with the smart-type and the non-smart-type field devices via network server/client pairs.

20. A process control system comprising:

a plurality of field devices of multiple different field device types including smart-type field devices and non-smart-type field devices;

a plurality of distributed controllers coupled to the field devices;

a workstation coupled to the distributed controllers; and

a plurality of control means that are selectively defined and created at configuration by a user to define and create a control strategy, and installed on ones of the plurality of distributed controllers, the plurality of control means including control means executable in the distributed controllers and control means executable in processing units in the smart-type field devices, the smart-type field devices being controlled by control means executable independently and in parallel in the distributed controllers and in the smart-type field device processing units, and the non-smart-type field devices being controlled by control means executable in the distributed controllers, the control means controlling the smart-type field devices and the non-smart-type field devices to implement smart-type field device standards on both the smart-type field devices and non-smart-type field devices so that standard control operation is transparent to a user.

21. A process control system according to claim 20, wherein the smart-type field devices include Fieldbus standard field devices.

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

means for interfacing with a user;

wherein

the smart-type and the non-smart-type field devices operate in compliance with defined bus-based architecture standards and the plurality of control means perform smart-type control operations and non-smart-type control operations transparent to the user over the interfacing means.

23. A process control system according to claim 20, wherein the plurality of control means distributed on the plurality of distributed controllers perform smart-type control operations operating on the smart-type field devices and non-smart-type operations operating on the non-smart-type field devices independently, simultaneously and in parallel.

24. A process control system according to claim 20 wherein ones of the control means perform different control operations.

38. A process control system according to claim 20 wherein the plurality of control means communicate with the smart-type and the non-smart-type field devices via network server/client pairs.

25. An executable program code implementing a process control system for controlling a plurality of field devices of multiple different field device types including smart-type field devices and non-smart-type field devices, the process control system including a plurality of distributed controllers coupled to the field devices, the executable program code comprising:

a software system including a plurality of control modules that are selectively defined and created at configuration by a user to define and create a control strategy, and installed on ones of the plurality of distributed controllers; and

a communication and control routine including control modules executable in the distributed controllers and control modules executable in processing units in the smart-type field devices, the smart-type field devices being controlled by control modules executable independently and in parallel in the distributed controllers and in the smart-type field device processing units and the non-smart-type field devices being controlled by control modules executable in the distributed controllers, the control modules controlling the smart-type and the non-smart-type field devices to implement smart-type field device standards on both the smart-type field devices and non-smart-type field devices so that standard control operation is transparent to a user.

26. An executable program code according to claim 25 wherein the smart-type field devices include Fieldbus standard field devices.

27. An executable program code according to claim 25 further comprising:

a user interface for interfacing with a user;

wherein;

the smart-type and the non-smart-type field devices operate in compliance with defined bus-based architecture standards and the software system performs smart-type control operations and non-smart-type control operations transparent to the user over the user interface.

28. An executable program code according to claim 25 wherein the software system performs smart-type control operations using the plurality of control modules distributed on the plurality of distributed controllers operating on the smart-type field devices and non-smart-type operations operating on the non-smart-type field devices independently, simultaneously and in parallel.

29. An executable program code according to claim 25 wherein ones of the controllers perform different control operations.

30. An executable program code according to claim 25 wherein the software system further includes:

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

31. An executable program code according to claim 25 wherein the control modules are selectively installable by downloading a selected control module to a controller of the plurality of distributed controllers.

32. An executable program code according to claim 25 wherein the control modules are objects in an object-oriented environment.

33. An executable program code according to claim 25 wherein the plurality of control modules is configured into a communication services hierarchy including:

a remote object communications (ROC) level for communicating messages between two control modules in a same controller and between two control modules in different controllers, and

a low level communications level for interfacing with communications hardware and transmitting messages across the communications hardware.

34. An executable program code according to claim 25 wherein the control modules include a device connection object for controlling data transfers between a plurality of devices, transmitting data, maintaining communication link status between two communicating devices and establishing a communication link upon demand of a remote device.

35. An article of manufacture encoding the executable program code according to claim 25.

39. An executable program code according to claim 25 wherein the software system communicates with the smart-type and the non-smart-type field devices via network server/client pairs.