Process control network with redundant field devices and buses

• US 6,047,222 A
• Filed: 12/30/1997
• Issued: 04/04/2000
• 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:
  US08/983,019
• Time in Patent Office: 826 Days
• Field of Search: 370/216-218, 370/222-225, 700/1, 700/2, 700/3, 700/4, 700/79, 700/80, 700/81, 700/82, 700/83, 709/200, 709/201, 709/208, 709/209, 709/210, 709/211, 714/2, 714/6, 714/11
• US Class Current: 700/79
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 19/41855 by local area network [LAN], network structure
• CPC Class Codes: G05B 2219/24175 Redundant communication channel, if one fails use the other
• CPC Class Codes: G05B 2219/24182 Redundancy
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31245 Redundant bus, interbus, with two masters
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Functional elements within a two-wire, loop-powered, two-way digital communications environment are interconnected using selective redundant connections and selective redundant functional elements. The redundant functional elements and redundant connections provide a smooth transition from operation of a primary process loop element to a secondary process loop element in the event of a failure of the primary process loop element. Redundancy is selectively implemented using a redundant pair of field devices or a redundant bus pair having a primary bus and a redundant bus. In a first case, redundancy is selectively implemented using a single set of communication media, such as a single communication loop, but implementing redundant functional elements, such as field devices, so that recovery is achieved upon failure of a functional element but not upon failure of the communication media. In a second case, redundancy is selectively implemented using a redundant set of communication media in addition to use of redundant devices so that recovery is attained both for a failing device and a failing communication media. In a third case, redundancy is selectively implemented using a redundant set of communication media but using a single device so that recovery is attained for a failing communication media but not for a failing device.

Claims

1. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process; and

a controller communicatively coupled to the pair of redundant elements via the communication bus to detect a failure of one of the redundant elements using the communication bus and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements.

2. The process control system of claim 1, wherein the communication bus implements a two-wire, two-way, loop-powered digital communication protocol.

3. The process control system of claim 2, wherein the communication protocol is a Fieldbus communication protocol.

4. The process control system of claim 1, wherein the communication bus implements a four-wire communication protocol.

5. The process control system of claim 1, wherein the communication bus implements a two-wire, two-way, loop-powered, mixed digital and analog communication protocol.

6. The process control system of claim 1, wherein the primary redundant element comprises one of the plurality of devices and the secondary redundant element comprises a further device that is coupled to the communication bus.

7. The process control system of claim 6, wherein the primary redundant device and the secondary redundant device are valves that are operatively connected in parallel to each other in the process.

8. The process control system of claim 6, wherein the primary redundant device and the secondary redundant device are transmitters that are operatively connected in serial to each other in the process.

9. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process; and

a controller coupled to the pair of redundant elements to detect a failure of one of the redundant elements and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements;

wherein the primary redundant element comprises the communication bus and the secondary redundant element comprises a further communication bus.

10. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process; and

a controller coupled to the pair of redundant elements to detect a failure of one of the redundant elements and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements;

wherein the primary redundant element comprises a first function block that performs a particular process function and the secondary redundant element comprises a second function block that performs the particular process function.

11. The process control system of claim 10, wherein the first and second function blocks are located in different ones of the plurality of field devices.

12. The process control system of claim 10, wherein the controller includes a further function block communicatively coupled to the first and the second function blocks that detects a malfunction of one of the first and the second function blocks.

13. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process; and

a controller coupled to the pair of redundant elements to detect a failure of one of the redundant elements and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements;

wherein the primary redundant element comprises a loop including the communication bus connected to one of the devices and the secondary redundant element comprises a redundant loop including a redundant communication bus connected to a redundant device.

14. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process;

a controller coupled to the pair of redundant elements to detect a failure of one of the redundant elements and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements; and

a control logic operating in a functional element associated with the pair of redundant elements, the control logic adapted to detect an operational status of one of the redundant elements and to communicate the operational status to the controller.

15. A process control system that performs process control functions within a process in a distributed manner including:

a communication bus that performs a communication process function in the process;

a plurality of devices communicatively linked over the communication bus, wherein each of the devices performs a different process function within the process;

a pair of redundant elements including a primary redundant element and a secondary redundant element that are adapted to perform the same process function within the process; and

a controller coupled to the pair of redundant elements to detect a failure of one of the redundant elements and to operationally connect the other of the redundant elements in the process control system upon detection of the failure of the one of the redundant elements;

wherein the controller includes a detector that detects the termination of communications from one of the pair of redundant elements to detect the failure of the one of the pair of redundant elements.

16. A process control system comprising:

a loop controller including a control logic implementing a two-wire, two-way, loop-powered digital communication protocol;

a redundant pair of two-way communication busses coupled to the loop controller including a primary communication bus and a redundant communication bus; and

a plurality of devices coupled to the redundant pair of two-way communication busses;

wherein the controller is adapted to detect a failure associated with one of the redundant pair of busses and to operationally connect the other of the redundant pair of busses in the process control system upon detection of the failure of the one of the redundant pair of busses.

17. The process control system of claim 16, wherein the plurality of devices includes a first redundant device that is connected to the primary communication bus and a second redundant device that is coupled to the redundant communication bus.

18. The process control system of claim 16, wherein one of the plurality of devices is coupled to the primary communication bus and to the redundant communication bus.

19. The process control system of claim 16, wherein the loop controller implements a Fieldbus communication protocol.

20. A process control system comprising:

a loop controller including a control logic implementing a two-wire, two-way, loop-powered digital communication protocol;

a two-way communication loop coupled to the loop controller; and

a redundant pair of functional elements including a primary functional element coupled to the communication loop and a redundant functional element coupled to the communication loop;

wherein the loop controller is adapted to detect a failure associated with one of the redundant pair of functional elements via the two-way communication loop and to operationally connect the other of the functional elements in the process control system upon detection of the failure of the one of the functional elements.

21. A method of configuring a process control system that performs process control functions in a process in a distributed manner, the method including the steps of:

providing a communication bus that performs a communication process function in the process control system;

communicatively connecting a plurality of devices over the communication bus such that each of the devices performs a different process function within the process;

using a pair of redundant elements including a primary redundant element and a secondary redundant element within the process to perform the same process function; and

using the communication bus to detect a failure of one of the redundant elements; and

operationally connecting the other of the redundant elements in the process control system in response to the failure of the one of the redundant elements.

22. The method of claim 21, wherein the primary redundant element comprises the communication bus and the secondary redundant element comprises a further communication bus and further including the step of connecting the communication bus and the further communication bus to the same device.

23. The method of claim 21, wherein the primary redundant element comprises one of the plurality of devices and the secondary redundant element comprises a further device and further including the step of connecting the one of the plurality of devices and the further device to the communication bus.

24. The method of claim 21, wherein the primary redundant element comprises a primary loop including the communication bus connected to one of the devices and the secondary redundant element comprises a redundant loop including a redundant communication bus connected to a redundant device and further including the step of operationally connecting only one of the primary loop or the redundant loop within the process control system at a particular time.

25. A method of configuring a process control system that performs process control functions in a process in a distributed manner, the method including the steps of:

providing a communication bus that performs a communication process function in the process control system;

communicatively connecting a plurality of devices over the communication bus such that each of the devices performs a different process function within the process;

using a pair of redundant elements including a primary redundant element and a secondary redundant element within the process to perform the same process function; and

detecting a failure of one of the redundant elements; and

operationally connecting the other of the redundant elements in the process control system in response to the failure of the one of the redundant elements;

wherein the primary redundant element comprises a first function block that performs a particular process function and the secondary redundant element comprises a second function block that performs the particular process function and further including the step of alternatively communicatively coupling either the first or the second function block within a process control loop of the process.

26. The method of claim 25, further including the step of locating the first and the second function blocks in different ones of the plurality of field devices.

27. The method of claim 25, further including the step of communicatively connecting a controller function block to the first and second function blocks to detect the failure of one of the first and second function blocks.