Process control system using a process control strategy distributed among multiple control elements

• US 6,195,591 B1
• Filed: 12/11/1998
• Issued: 02/27/2001
• 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: Stevenson, Dennis, Nixon, Mark, Webb, Arthur, Lucas, Mike, Havekost, Robert B., Jundt, Larry O., Ott, Michael G.
• Primary Examiner(s): Gordon, Paul P.
• Assistant Examiner(s): PATEL, RAMESH B
• Application Number:
  US09/209,780
• Time in Patent Office: 809 Days
• Field of Search: 700/2, 700/5, 700/18, 700/19, 700/26, 700/83, 700/87, 700/88, 700/89, 713/2, 713/100, 709/208, 709/213, 709/221, 709/222
• US Class Current: 700/83
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 2219/23261 Use control template library
• CPC Class Codes: G05B 2219/23298 Remote load of program, through internet
• CPC Class Codes: G05B 2219/23299 Remote load of program, through fieldbus
• CPC Class Codes: G05B 2219/23424 Select construction element from function library
• CPC Class Codes: G05B 2219/25232 DCS, distributed control system, decentralised control unit
• CPC Class Codes: G05B 2219/25323 Intelligent modules
• 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 process controller implements an overall, user-developed control strategy in a process control network that includes distributed controller and field devices, such as Fieldbus and non-Fieldbus devices. A user defines the control strategy by building a plurality of function blocks and control modules and downloading or installing user-specified portions of the control strategy into the Fieldbus devices and the non-Fieldbus devices. Thereafter, the Fieldbus devices automatically perform the downloaded portions of the overall strategy independently of other portions of the control strategy. For example in a process control system that includes distributed field devices, controllers and workstations, portions of the control strategy downloaded or installed into the field devices operate independently of and in parallel with the control operations of the controllers and the workstations, while other control operations manage the Fieldbus devices and implement other portions of the control strategy.

Claims

1. A computer program product on a computer usable medium for use in a process control system distributed through a network connecting a workstation, a field device, and a controller coupled to the field device, the computer program product comprising:

a bootstrap loading program for bootstrap loading the process control system to control the field device including;

a startup information assignment routine that assigns network connectivity information to the controller;

a broadcast protocol routine that broadcasts a message-oriented protocol to a protocol boot port in the network, the message-oriented protocol being broadcast via a boot server that matches the address of the field device with an assigned identifier and internet protocol address, and echoes the field device address to the protocol boot port;

a receive protocol routine executable in the boot port that receives the message-oriented protocol, matches the echoed field device address with an address in the message-oriented protocol, and sets network connectivity information in the boot port if the message-oriented protocol is received;

an acknowledge protocol receipt routine executable in the controller that returns a message to the boot server indicative of an operational condition of the controller;

a field device configuration routine for configuring device address, name and number information associating the field device and the network; and

a download routine that downloads control program code to the controller.

2. A computer program product according to claim 1 wherein:

the startup information assignment routine assigns at least one item of connectivity information to the controller, the items selected from among an internet protocol address, a node name, a media access address (MAC), a device ID, an area control network (ACN) link number, and process control network (PCN) network number.

3. A computer program product according to claim 2 wherein:

the startup information assignment routine includes a routine that calculates the internet protocol address based on the device ID, the ACN link number, and the PCN link number.

4. A computer program product according to claim 1 wherein:

the broadcast protocol routine sends a message-oriented protocol datagram which designates default primary and secondary internet protocol addresses that are reserved as protocol boot ports.

5. A computer program product according to claim 1 wherein:

the acknowledge protocol routine returns a message to the boot server addressed according to the network connectivity information.

6. A computer program product according to claim 1 wherein:

the field device configuration routine includes;

a user-interactive routine in which a user enters a Device Name, Device MAC Address, ACN Link Number and PCN Network Number;

a configuration routine that automatically assigns a device ID to the field device; and

a communications subsystem that calculates internet protocol addresses for the field device from the configured ACN Link number, PCN Network Number and the assigned device ID.

7. A computer program product according to claim 1 wherein:

the download routine flash downloads the control program code over the ACN network by passing messages and S-Record files between devices on the ACN.

8. A computer program product on a computer usable medium for use in a process control system distributed through a network connecting a workstation, a field device, and a controller coupled to the field device, the computer program product comprising:

a means for bootstrap loading the process control system to control the field device including;

means for assigning network connectivity information to the controller;

means for broadcasting a message-oriented protocol to a protocol boot port in the network, including;

means for broadcasting the message-oriented protocol via a boot server that matches the address of the field device with an assigned identifier and internet protocol address, and echoes the field device address to the protocol boot port;

means executable in the boot port for receiving the message-oriented protocol including;

means for matching the echoed field device address with an address in the message-oriented protocol, and

means for setting network connectivity information in the boot port if the message-oriented protocol is received;

means executable in the controller for returning a message to the boot server acknowledging receipt of the protocol and indicative of an operational condition of the controller;

means for configuring device address, name and number information associating the field device and the network; and

means for downloading control program code to the controller.

9. A computer program product according to claim 8 wherein:

the means for assigning assigns at least one item of connectivity information to the controller, the items selected from among an internet protocol address, a node name, a media access address (MAC), a device ID, an area control network (ACN) link number, and process control network (PCN) network number.

10. A computer program product according to claim 9 wherein:

the means for assigning includes;

means for calculating the internet protocol address based on the device ID, the ACN link number, and the PCN link number.

11. A computer program product according to claim 8 wherein:

the means for broadcasting sends a message-oriented protocol datagram which designates default primary and secondary internet protocol addresses that are reserved as protocol boot ports.

12. A computer program product according to claim 8 wherein:

the means for returning returns a message to the boot server addressed according to the network connectivity information.

13. A computer program product according to claim 8 wherein:

the means for configuring includes;

means for interacting with a user, the user entering a Device Name, Device MAC Address, ACN Link Number and PCN Network Number;

means for automatically assigning a device ID to the field device; and

means for calculating internet protocol addresses for the field device from the configured ACN Link number, PCN Network Number and the assigned device ID.

14. A computer program product according to claim 8 wherein:

the downloading means downloads the control program code over the ACN network by passing messages and S-Record files between devices on the ACN.

15. A method of defining a control strategy during operation of a process control system, the process control system executing process control operations and including a controller and a field device, the method comprising:

defining a control strategy;

creating a plurality of function blocks and control strategy modules according to the control strategy definition, the function blocks and control strategy modules being selected from previously-defined function blocks and control modules including standard function blocks, and new user-defined custom function blocks and control modules;

building the plurality of function blocks and control strategy modules according to the control strategy definition; and

distributively downloading user-specified function blocks and control strategy modules selectively among the distributed controller and the distributed field device for executing the user-specified function blocks and control strategy modules independently and in parallel.

16. A method according to claim 15 wherein the process control system includes a plurality of distributed controllers and a plurality of distributed field devices, the field devices including Fieldbus standard devices executing Fieldbus standard function blocks.

17. A method according to claim 15 wherein the process control system includes a plurality of distributed controllers and a plurality of distributed field devices, the field devices including Fieldbus standard devices executing Fieldbus standard function blocks and nonFieldbus standard devices executing in the manner of Fieldbus standard function blocks.

18. A computer program product including a computer usable medium having computable readable code embodied therein implementing the method according to claim 15.

19. An article of manufacture storing an executable program code implementing the method according to claim 15.

20. A computer program product on a computer usable medium for use in a process control system distributed through a network connecting a workstation, a field device, and a controller coupled to the field device, the computer program product comprising:

a controller implementing a control strategy of the process control system, the control strategy being selectively implemented via a user interface, the software system including;

a plurality of control strategy modules that are selectively distributed using the user interface among the field device, controller and workstation,

the control strategy modules including predefined standard control modules and custom control strategy modules that are defined and created by a user via the user interface, the user defining and setting control module attributes, the control strategy modules and control module attributes specifying the control strategy,

the control strategy modules operating mutually independently and in parallel.

21. A computer program product on a computer usable medium for use in a process control system distributed through a network connecting a workstation, a field device, and a controller coupled to the field device, the computer program product comprising:

a controller implementing a control strategy of the process control system;

a user interface; and

a configuration routine for user-selectively and interactively;

defining and creating the 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

user-selectively distributing the control strategy modules among the field device, the controller, and the workstation.