Schematic generator for use in a process control network having distributed control functions

• US 6,088,665 A
• Filed: 11/03/1997
• Issued: 07/11/2000
• Est. Priority Date: 11/03/1997
• 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): Hoff, Marc S.
• Assistant Examiner(s): MILLER, CRAIG S
• Application Number:
  US08/962,630
• Time in Patent Office: 981 Days
• Field of Search: 702/90, 702/91, 702/194, 702/116, 702/127, 702/188, 364/138, 364/139, 364/188, 395/200.47, 395/200.48, 395/200.53, 395/200.83
• US Class Current: 702/188
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A schematic generator for use in a process control network, in which control functions are implemented by field devices interconnected at various and distributed locations on a bus, polls each of the field devices to retrieve information pertaining to the identity of the device, the identity of the control functions associated with the device, the manner in which the device communicates with other devices with respect to each of the control functions associated with that device, the timing associated with the execution of each of the control functions of that device and the timing of the communication activities associated with each of the control functions of that device. The schematic generator then analyses the retrieved data to identify the manner in which the devices are physically connected on the bus and the manner in which the different control functions are interconnected over the bus to perform process control loops within the process control network. Thereafter, the schematic generator creates one or more schematics, such a maintenance schematic illustrating the physical layout of the field devices in the process control network, a control loop schematic illustrating the interconnections between functions within one or more of the deceives that form a control loop, and a timing schematic illustrating the timing of or the amount of communications occurring on the bus.

Claims

1. A schematic generator for use with a process control network having a plurality of devices that communicate over a bus, wherein each of the devices is capable of performing a process control function and stores linkage data pertaining to the manner in which the devices are configured to operate within the process control network, the schematic generator comprising:

a device interrogator that interrogates each of the devices over the bus to retrieve the linkage data stored in each of the devices;

a data analyzer that analyses the retrieved linkage data to determine current process control configuration information; and

a generator that creates a graphical schematic illustrating a current process control configuration of the process control network using the current process control configuration information.

2. The schematic generator of claim 1, wherein the linkage data stored in at least one of the devices comprises device physical connection data, wherein the data analyzer identifies physical interconnections between the devices and the bus, and wherein the graphical schematic comprises a maintenance schematic illustrating the physical interconnections between the devices and the bus.

3. The schematic generator of claim 2, wherein the linkage data stored in at least one of the devices further comprises device identity data, and wherein the generator includes means for displaying an indication of an identity of one of the devices on the maintenance schematic.

4. The schematic generator of claim 2, wherein the linkage data stored in at least one of the devices further comprises process control function data indicating one or more function blocks capable of being performed by the devices, wherein the data analyzer identifies a function block within the one of the devices, and wherein the generator further includes means for indicating the identified function block as being associated with the one of the devices on the maintenance schematic.

5. The schematic generator of claim 4, wherein the linkage data stored in at least one of the devices further includes function block communication data pertaining to the manner in which the function blocks are communicatively linked, wherein the data analyzer includes means for determining a control loop formed by communication links between the identified function block and one or more other function blocks within the process control network, and wherein the generator includes means for showing an indication of the determined control loop as being associated with the identified function block on the maintenance schematic.

6. The schematic generator of claim 5, wherein the data analyzer includes means for identifying an unassigned function block that is not communicatively linked to any other function block, and wherein the generator includes means for illustrating an indication of the unassigned function block.

7. The schematic generator of claim 1, wherein the linkage data stored in at least one of the devices comprises process control function data indicating function blocks capable of being performed by the devices and function block communication data pertaining to the manner in which the function blocks are communicatively linked, wherein the data analyzer includes means for identifying a control loop having a multiplicity of communicatively linked function blocks therein, and wherein the graphical schematic comprises a control loop schematic illustrating communication interconnections of the function blocks of the identified control loop.

8. The schematic generator of claim 7, wherein the identifying means includes means for determining a plurality of control loops formed by communicatively linked function blocks within the process control network.

9. The schematic generator of claim 8, wherein the data analyzer includes means for locating an unassigned function block that is not communicatively connected within any of the plurality of control loops, and wherein the generator includes means for illustrating an indication of the unassigned function block.

10. The schematic generator of claim 7, wherein the linkage data stored in at least one of the devices includes device identity data, and wherein the generator includes means for illustrating an indication of an identity of a device in which one of the communicatively linked function blocks in the identified control loop is located.

11. The schematic generator of claim 7, wherein the data analyzer includes means for finding a connectivity conflict in the identified control loop and the generator includes means for illustrating the connectivity conflict on the control loop schematic.

12. The schematic generator of claim 1, wherein the linkage data stored in at least one of the devices includes communication destination data related to destinations of one of alarm data, event data, and trend data associated with the devices, and wherein the generator includes means for displaying a list of the destinations of the one of the alarm data, the event data and the trend data associated with one of the devices.

13. The schematic generator of claim 1, wherein the linkage data stored in at least one of the devices comprises process control function data indicating function blocks capable of being performed by the devices, communication timing data indicating scheduled bus communications times for the function blocks and function block execution time data specifying execution times associated with the function blocks, wherein the data analyzer includes means for determining periods of time associated with the execution of each of a multiplicity of the function blocks and periods of time associated with scheduled bus communications for each of the multiplicity of the function blocks, and wherein the graphical schematic comprises a timing schematic illustrating the execution periods and the scheduled bus communication periods associated with each of the multiplicity of the function blocks.

14. The schematic generator of claim 13, wherein the data analyzer includes means for identifying timing conflicts associated with the execution periods and the scheduled bus communication periods, and wherein the schematic generator includes means for illustrating a determined timing conflict on the timing schematic.

15. The schematic generator of claim 1, wherein the linkage data stored in at least one of the devices comprises communication timing data associated with communications on the bus, wherein the data analyzer includes means for computing a bandwidth indication associated with a segment of the bus from the communication timing data, and wherein the graphical schematic comprises a communication schematic illustrating the bandwidth indication in conjunction with the bus segment associated with the bandwidth indication.

16. The schematic generator of claim 15, further including means for polling a selected device to retrieve statistical device communication data, and wherein the generator includes means for displaying the retrieved statistical device communication data on the communication schematic.

17. The schematic generator of claim 1, wherein the generator includes means for displaying multiple graphical schematics illustrating different types of process control configurations for a common element of the process control network and means for enabling a user to switch between the multiple schematics based on an indication of the common element.

18. A computer program product for use in a process control network having a bus, a plurality of devices capable of performing process control functions connected to the bus and a device linkage database that stores linkage data pertaining to the manner in which the devices are configured to operate within the process control network, the computer program product comprising:

a computer useable medium having computer readable code therein including;

a first routine that interrogates the linkage database to retrieve the linkage data pertaining to each of the devices;

a second routine that analyses the retrieved linkage data to determine current process control configuration information; and

a third routine that creates a graphical schematic illustrating a current process control configuration for the process control network using the current process control configuration information.

19. The computer program product of claim 18, wherein each of the devices includes a device database making up a portion of the linkage database and further including a fourth routine that controls the first routine to serially interrogate the device databases making up the linkage database to obtain the linkage data.

20. The computer program product of claim 18, wherein the linkage data comprises device identity data and process control function data indicating one or more function blocks capable of being performed by the devices, and wherein the graphical schematic comprises a maintenance schematic illustrating physical interconnections between the devices and illustrating the function blocks associated with one or more of the devices.

21. The computer program product of claim 20, wherein the linkage data further comprises function block communication data pertaining to the manner in which the function blocks of each device are communicatively linked to other function blocks within the process control network, wherein the second routine identifies a set of process control loops formed by the function blocks in the process control network, and wherein the third routine displays an indication of the process control loop with which one of the illustrated function blocks is associated.

22. The computer program product of claim 18, wherein the linkage data comprises process control function data indicating one or more function blocks capable of being performed by the devices and function block communication data pertaining to the manner in which the function blocks of each device are communicatively linked to other function blocks within the process control network, wherein the second routine identifies a set of process control loops formed by the function blocks in the process control network, and wherein the graphical schematic comprises a control loop schematic illustrating one of the identified process control loops.

23. The computer program product of claim 18, wherein the linkage data comprises process control function data indicating one or more function blocks capable of being performed by the devices, function block execution timing data and function block bus communication scheduling data, wherein the second routine determines the periods of time associated with the execution of each of a multiplicity of the function blocks and the periods of time associated with scheduled bus communications for each of the multiplicity of the function blocks, and wherein the graphical schematic comprises a timing schematic illustrating the execution periods and the scheduled bus communication periods associated with each of the multiplicity of the function blocks.

24. The computer program product of claim 18, wherein the linkage data comprises process control function data indicating one or more function blocks capable of being performed by the devices, function block communication timing data pertaining to the times that the function blocks communicate on the bus, wherein the second routine determines a bandwidth calculation associated with the communications occurring on a segment of the bus, and wherein the graphical schematic comprises a communication schematic illustrating the bus segment and the bandwidth calculation associated with the bus segment.

25. A method of generating a schematic in a process control network having a plurality of devices that communicate over a bus, wherein each of the devices is capable of performing a process control function and stores linkage data pertaining to the manner in which the device is configured to operate within the process control network, the method comprising the steps of:

interrogating each of the devices over the bus to retrieve the linkage data stored in each of the devices;

analyzing the retrieved linkage data to determine current process control configuration information; and

creating a graphical schematic illustrating a process control configuration of the process control network using the determined current process control configuration information.

26. The method of claim 25, wherein the linkage data stored in at least one of the devices comprises device identity data and process control function data indicating one or more function blocks capable of being performed by the devices, and wherein the step of creating includes the step of producing a maintenance schematic that illustrates physical connections between the devices and the bus and that illustrates the function blocks associated with one or more of the illustrated devices.

27. The method of claim 25, wherein the linkage data stored in at least one of the devices further comprises function block communication data pertaining to the manner in which the function blocks are communicatively linked within the process control network, wherein the analyzing step includes the step of identifying a set of process control loops formed by communicatively linked function blocks, and wherein the creating step includes the step of displaying, on the maintenance schematic, an indication of the process control loop with which one of the displayed function blocks is associated.

28. The method of claim 25, wherein the linkage data stored in at least one of the devices comprises process control function data indicating one or more function blocks capable of being performed by the devices and function block communication data pertaining to the manner in which the function blocks are communicatively linked, wherein the analyzing step includes the step of identifying a set of process control loops formed by communicatively linked function blocks, and wherein the step of creating includes the step of producing a control loop schematic depicting one of the identified process control loops.

29. The method of claim 25, wherein the linkage data stored in at least one of the devices comprises process control function data indicating one or more function blocks capable of being performed by the devices, function block execution timing data and function block bus communication scheduling data, wherein the analyzing step includes the step of determining the periods of time associated with the execution of a multiplicity of the function blocks and the periods of time associated with scheduled bus communications for each of the multiplicity of the function blocks, and wherein the step of creating includes the step of producing a timing schematic that illustrates the function block execution periods and the scheduled bus communication periods associated with each of the multiplicity of the function blocks.

30. The method of claim 25, wherein the linkage data stored in at least one of the devices comprises process control function data indicating one or more function blocks capable of being performed by the devices, function block bus communication timing data pertaining to the times that the function blocks communicate on the bus, wherein the step of analyzing includes the step of producing a bandwidth calculation associated with communications occurring on a segment of the bus, and wherein the step of creating includes the step of producing a schematic that illustrates the bus segment and the bandwidth calculation associated with the bus segment.