Method and apparatus for debugging and tuning a process control network having distributed control functions

• US 6,044,305 A
• Filed: 12/30/1997
• Issued: 03/28/2000
• Est. Priority Date: 10/04/1996
• Status: Expired due to Term

• Current Assignee: Fisher Controls International LLC (Emerson Electric Company)
• Original Assignee: Fisher Controls International LLC (Emerson Electric Company)
• Inventors: Larson, Brent H., Brown, Larry K., Burns, Harry A.
• Primary Examiner(s): Gordon, Paul P.
• Assistant Examiner(s): PATEL, RAMESH B
• Application Number:
  US08/983,020
• Time in Patent Office: 819 Days
• Field of Search: 700/87-89, 700/2, 700/4, 700/11, 700/13, 700/14, 700/17, 700/18, 700/19, 700/47-52, 709/100, 709/102, 709/103, 709/201, 710/260-264
• US Class Current: 700/87
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31113 General, vendor indenpendant display and control interface for sensor actuator
• CPC Class Codes: G05B 2219/31119 Fielddevice comprises also controller and pneumatic actuator and sensor
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31211 Communicate diagnostic data from intelligent field device controller to central
• CPC Class Codes: G05B 2219/33273 DCS distributed, decentralised controlsystem, multiprocessor
• CPC Class Codes: G05B 2219/33326 Analyzer, diagnostic for servovalve
• CPC Class Codes: G05B 2219/34427 Diagnostic, monitoring incorporated in controller
• CPC Class Codes: G05B 2219/45226 Process control
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system and method for debugging and tuning a process control network having distributed control functions implemented by a set of field devices communicatively linked over a bus includes an operational scheduler that schedules the execution of each of a number of process control functions and communication functions performed by the field devices to define a process control scheme and an indicator that indicates one or more process control scheme locations at which the process control scheme is to be automatically or conditionally interrupted to thereby enable debugging and/or tuning of the process control network. A controller interrupts execution of the process control scheme at the indicated flow locations, communicates process data to a user to display the current or a past state of the process to a user and waits for user input before continuing with operation of the process control scheme. In a tuning mode, the controller delivers data pertaining to a process parameter to a tuning device or to a user which determines a new tuning parameter, such as a gain, to be used within the process control scheme based on the process parameter data.

Claims

1. A system for use in debugging or tuning a process control network having distributed control functions implemented by a plurality of field devices communicatively linked over a bus, wherein each of the field devices is capable of performing one or more process control functions and one or more communication functions, the system comprising:

a process control operation scheduler that schedules the execution of each of the process control functions and the communication functions performed by the plurality of devices to define a process control scheme;

an indicator that indicates a process control scheme location implemented by one of the plurality of field devices at which the process control scheme is to be interrupted when the process control scheme is in a debugging/tuning mode; and

a controller that stops execution of the process control scheme at the indicated flow location when the indicated flow location is reached and the process control scheme is in the debugging/tuning mode.

2. The system of claim 1, wherein the scheduler controls communication over the bus by sending communication enabling messages to the plurality of field devices and wherein the controller is coupled to the scheduler to prevent the scheduler from sending communication enabling messages to the field devices when the process control scheme is at the indicated process control scheme location to thereby interrupt the process control scheme.

3. The system of claim 1, wherein the controller further includes a communicator that receives instructions from a host device communicatively connected to the bus and means for causing the operation of the process control scheme to continue in response to user input at the host device.

4. The system of claim 3, wherein the communicator includes means for retrieving process control data pertaining to the state of the process when the process control scheme is interrupted and means for sending the retrieved process control data to the host device for display to a user.

5. The system of claim 3, wherein the indicator indicates a conditional breakpoint in the process control scheme and the indicator includes means for storing a condition associated with the conditional breakpoint and means for determining if the condition associated with the conditional breakpoint is satisfied when the conditional breakpoint is reached within the process control scheme.

6. The system of claim 3, wherein the indicator indicates a multiplicity of single-step stopping points in the process control scheme.

7. The system of claim 3, wherein the indicator indicates a tuning stopping point within the process control scheme, and wherein the system further includes means for storing process data for a process parameter generated before the process control scheme is interrupted, a tuner that determines a process tuning parameter for the process control network based on the stored process data and means for communicating the process tuning parameter to one of the plurality of field devices.

8. The system of claim 7, wherein the process tuning parameter is a gain.

9. The system of claim 1, wherein the indicator indicates one of the plurality of field devices so that the process control scheme is interrupted when the one of the plurality of field devices is scheduled to operate within the process control scheme.

10. The system of claim 1, wherein the indicator indicates an instruction address within one of the functions of the one of the plurality of field devices to cause interruption of the process control scheme when the instruction address is implemented in the process control scheme.

11. The system of claim 1, wherein the indicator indicates a function of the one of the plurality of field devices to cause interruption of the process control scheme when the function is implemented by the one of the plurality of field devices in the process control scheme.

12. The system of claim 1, wherein the controller includes means located in at least the one of the plurality of field devices for interrupting operation of a function performed by the one of the plurality of field devices when the indicated location is associated with the operation of the one of the plurality of field devices.

13. The system of claim 1, wherein the controller includes interrupting means located in each of the plurality of field devices, wherein each of the interrupting means interrupts operation of a function performed by an associated field device when the indicated location is associated with the operation of the associated field device.

14. A method of debugging or tuning a process control network having distributed control functions implemented by a plurality of field devices communicatively linked over a bus, wherein each of the field devices is capable of performing one or more process control functions and one or more communication functions, the method comprising the steps of:

scheduling an order of execution for the process control functions and the communication functions to define a process control scheme;

marking one or more process control scheme locations associated with the process control functions or the communication functions at which the process control scheme is to be interrupted;

running the process control scheme;

detecting when any one of the plurality of field devices implements a control function or a communication function making up one of the marked process control scheme locations;

interrupting execution of the process control scheme at the one marked process control scheme location;

waiting for a user to indicate that execution of the process control scheme should continue; and

starting the process control scheme at the one marked location upon receipt of a user indication that execution of the process control scheme should continue.

15. The method of claim 14, wherein the step of running the process control scheme includes the step of sending communication enabling messages to different ones of the plurality of field devices at different times and the step of interrupting execution of the process control scheme includes the step of discontinuing the step of sending communication enabling messages until receipt of the user indication.

16. The method of claim 14, further including the steps of retrieving process data pertaining to the state of the process when the process control scheme is interrupted and sending the retrieved process data via the bus to a host for display to a user.

18. The method of claim 14, wherein the step of marking includes the step of marking a multiplicity of the process control scheme locations as single-step stopping points.

19. The method of claim 14, wherein the step of marking includes the step of marking the one or more of the process control scheme locations as a process control tuning stopping point within the process control scheme, and wherein the method further includes the step of retrieving process data associated with a process parameter from one of the plurality of field devices before the process control scheme is interrupted, determining a process tuning parameter for the process control network using the stored process data and communicating the process tuning parameter to another of the plurality of field devices.

17. The method of 14, wherein the step of marking includes the steps of marking one of the process control scheme locations as a conditional breakpoint and storing a condition associated with the conditional breakpoint, and wherein the step of interrupting includes the steps of determining if the condition associated with the conditional breakpoint is satisfied when the process control scheme reaches the conditional breakpoint and automatically continuing with the process control scheme if the condition is not satisfied.

20. A process control device for use in a process control network having distributed control functions implemented by a plurality of field devices communicatively coupled to a bus, wherein each of the field devices includes one or more function blocks capable of performing an input function, an output function, or a control function within the process control network and capable of communicating on the bus, the process control device comprising:

a first function block that implements a process function to perform a portion of a process control scheme;

a memory that stores an indication of a point within the process control scheme associated with the first function block or with the device; and

a trace-tune function block communicatively coupled to the first function block including means for controlling the process control device to interrupt the process control scheme at the indicated point when the process control scheme reaches the indicated point.

21. The device of claim 20, wherein the first function block includes an algorithm that performs the process function and software that communicates via the bus after execution of the algorithm and wherein the indication indicates a point before or after execution of algorithm of the first function block.

22. The device of claim 20, wherein the first function block includes a set of instructions that perform the process function, wherein the indicated point is associated with one of the set of instructions and wherein the controlling means of the trace-tune function block stops operation of the first function block when the first function block reaches the indicated one of the set of instructions.

23. The device of claim 20, wherein the trace-tune function block includes means responsive to a user for restarting execution of the process control scheme at the indicated point.

24. The device of claim 20, wherein the trace-tune function block includes means for communicating process data from the process control device via the bus when the execution of the process control scheme is interrupted.

25. The device of claim 20, wherein the trace-tune function block further includes means for indicating a condition that must be satisfied at the indicated point, means for determining if the condition is satisfied at the indicated point and means for stopping execution of the process control scheme when the condition is satisfied at the indicated point.

26. The device of claim 20, wherein the trace-tune function block includes means for changing the mode of the first function block when the process control scheme reaches the indicated point.

27. The device of claim 20, wherein the trace-tune function block includes means for storing data associated with a process parameter during operation of the process control scheme and means for communicating the stored data via the bus when the process control scheme reaches the indicated point.

28. The device of claim 20, wherein the trace-tune function block includes means for communicating process data from the first function block via the bus when the process control scheme reaches the indicated point.