Interconnected zones within a process control system

• US 7,289,994 B2
• Filed: 04/09/2002
• Issued: 10/30/2007
• Est. Priority Date: 10/18/1999
• Status: Expired due to Term

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Nixon, Mark J., Beoughter, Ken, Havekost, Robert
• Primary Examiner(s): Rimell; Sam
• Assistant Examiner(s): Betit; Jacob F.
• Application Number:
  US10/119,269
• Publication Number:
  US 20020111948A1
• Time in Patent Office: 2,030 Days
• Field of Search: 707/2, 707/9, 707/103.R, 709/249, 709/225, 709/250, 713/201
• US Class Current: 1/1
• CPC Class Codes: G05B 15/00 Systems controlled by a computer G05B13/00, G05B19/00 take precedence; automatic controllers with particular characteristics G05B11/00
• CPC Class Codes: G05B 19/414 Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
• CPC Class Codes: G05B 19/4145 characterised by using same processor to execute programmable controller and numerical controller function [CNC] and PC controlled NC [PCNC]
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31092 Network server for communication between plc's, using server
• CPC Class Codes: G05B 2219/31156 Network structure, internet
• CPC Class Codes: G05B 2219/31208 Server node to watch, store message, variable, data between lon, network
• CPC Class Codes: G05B 2219/31324 Distributed real time knowledge, database
• CPC Class Codes: G05B 2219/31418 NC program management, support, storage, distribution, version, update
• CPC Class Codes: G05B 2219/31422 Upload, download programs, parameters from, to station to, from server
• CPC Class Codes: G05B 2219/33125 System configuration, reconfiguration, customization, automatic
• CPC Class Codes: G05B 2219/36103 Adapt, update machining parameters automatically as function of state of processing
• CPC Class Codes: G06F 15/16 Combinations of two or more digital computers each having at least an arithmetic unit, a program unit and a register, e.g. for a simultaneous processing of several programs coordinating program control therefor G06F9/52; in regulating and control system G05B
• CPC Class Codes: G06F 16/25 Integrating or interfacing systems involving database management systems
• CPC Class Codes: H04B 7/15 Active relay systems
• CPC Class Codes: H04L 12/28 characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks] wireless communication networks H04W ; arrangements for dividing the transmission path H04W40/00
• 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 control system includes multiple zones containing process control network communicatively interconnected to exchange information necessary to monitor the system and to perform process control. Each zone may include an inter-zone server that controls the exchange of information between the zones via communication links. In addition to controlling the routing of information between the zones, the inter-zone servers may perform additional processing on the information being exchanged, such as security monitoring, language translation and version control.

Claims

1. A method of transferring data in a process control system having a first process control network having a first inter-zone server and a second process control network having a second inter-zone server, wherein the first process control network operates under a first version of software and the second process control network operates under a second version of the software, the method comprising the steps of:

formatting a process control message in the first process control network, wherein the process control message contains a device name for a receiving device to which the process control message is being transmitted, and wherein the device name is defined for the receiving device within the process control system;

communicating the process control messages within the first process control network to the first inter-zone server;

determining at the first inter-zone server the process control network in which the receiving device is located based on the device name in the process control message;

converting process control messages from a format compatible with the first version of the software to a format compatible with the second version of the software and communicating the process control messages from the first inter-zone server to the second inter-zone server ia a first communication link in response to determining that the receiving device is located in the second process control network; and

communicating the process control messages from the second inter-zone server to the second process control network.

2. The method of claim 1, wherein the process control system has a third process control network having a third inter-zone server, the method further comprising the steps of:

formatting process control messages in the third process control network, wherein the process control message contains a device name for a receiving device to which the process control message is being transmitted;

communicating the process control messages within the third process control network to the third inter-zone server;

determining at the third inter-zone server the process control network in which the receiving device is located based on the device name in the process control message;

communicating the process control message from the third inter-zone server to the first process control network via a second communication link in response to determining that the receiving device is located in the second process control network;

communicating the process control messages from the first process control network to the second inter-zone server via the first communication link in response to determining that the receiving device is located in the second process control network; and

communicating the process control messages from the second inter-zone server to the second process control network.

3. The method of claim 1, wherein the first process control network has a first unique name and the second process control network has a second unique name defined for the process control networks within the process control system, wherein the formatting step comprises the step of formatting process control messages with the second unique name, the method further comprising the step of determining at the first inter-zone server to communicate process control messages to the second inter-zone server based on the second unique name in the process control messages.

4. The method of claim 1, wherein the formatting step comprises the step of formatting process control messages with the authorization information, the method further comprising the steps of:

determining at the first inter-zone server whether the process control messages received at the first inter-zone server are authorized for transfer to the second process control network; and

communicating the process control messages from the first inter-zone server to the second inter-zone server based on the determination that the process control messages are authorized for transfer to the second process control network.

5. The method of claim 1, wherein the formatting step comprises the step of formatting process control messages with the authorization information, the method further comprising the steps of:

determining at the second inter-zone server whether the process control messages received at the second inter-zone server are authorized for receipt by the second process control network; and

communicating the process control messages from the second inter-zone server to the second process control network based on the determination that the process control messages are authorized for receipt by the second process control network.

6. The process control system of claim 5, wherein the authorization information of the process control messages is user information, the determination step comprising the step of evaluating the user information to determine whether the process control messages received at the second inter-zone server are authorized for receipt by the second process control network.

7. The method of claim 1, wherein the first process control network operates under a first alarm priority configuration and the second process control network operates under a second alarm priority configuration, the method further comprising the step of converting alarm information in process control messages from a format compatible with the first alarm priority configuration to a format compatible with the second alarm priority configuration.

8. The method of claim 1, wherein the first process control network is configured to use process control messages in a first verbal language and the second process control network is configured to use process control messages in a second verbal language, the method further comprising the step of translating process control messages in the first verbal language to process control messages in the second verbal language.

9. The method of claim 1, wherein the process control messages are condition monitoring messages.

10. A process control system comprising:

a first process control network having a first inter-zone server and a plurality of field devices operatively connected to the first inter-zone server, wherein the field devices perform process control functions and transmit process control messages in the first process control network;

a second process control network having a second inter-zone server and a plurality of field devices operatively connected to the second inter-zone server, wherein the field devices perform process control functions and transmit process control messages in the second process control network;

a first communication link that communicatively couples the first inter-zone server and the second inter-zone server; and

a communication routine stored in each of the first and the second inter-zone servers that uses the first communication link to transfer process control messages from the first process control network to the second process control network, and from the second process control network to the first process control network,

wherein the process control messages contain a device name for a receiving device to which the process control message is being transmitted, wherein the device name is defined for the receiving device within the process control system, and the communication routine of the inter-zone server for the process control network of the field device transmitting the process control message uses the device name in the process control message to determine the process control network for the receiving device and transfers the process control message over the first communication link to the other process control network in response to determining that the receiving device is located in the other process control network, and

wherein the first process control network operates under a first version of process control network software and the second process control network operates under a second version of the process control network software, the system further comprising a version control routine that converts process control messages from a format compatible with the first version of the process control network software to a format compatible with the second version of the process control network software when the process control messages are transferred from the first process control network to the second process control network.

11. The process control system of claim 10, further comprising:

a third process control network having a third inter-zone server having a communication routine and a plurality of field devices operatively connected to the third inter-zone server, wherein the field devices perform process control functions and transmit process control messages in the third process control network; and

a second communication link that communicatively couples the third inter-zone server to the first inter-zone server;

wherein process control messages transmitted from field devices in the third process control network to receiving devices in the second process control network as determined by the communication routine of the third inter-zone server based on the device name in the process control messages are transferred from the third process control network to the first process control network using the second communication link and from the first process control network to the second process control network using the first communication link.

12. The process control system of claim 10, wherein the first process control network is configured to use process control messages in a first verbal language and the second process control network is configured to use process control messages in a second verbal language, one of the first and the second inter-zone servers having a language translation routine that converts process control messages in the first verbal language to process control messages in the second verbal language when process control messages are transferred from the first process control network to the second process control network.

13. The process control system of claim 10, the first process control network having a first device with a first device name and being communicatively connected to the first inter-zone server, the second process control network having a second device with a second device name and being communicatively connected to the second inter-zone server, the second device communicating process control messages containing the first device name to the second inter-zone server, the system further comprising a name routine stored in the second inter-zone server that uses the first device name in the process control messages of the second device to cause the communication routine to use the first communication link to transfer the process control messages containing the first device name from the second process control network to the first process control network.

14. The process control system of claim 10, wherein the process control messages contain authorization information, and the system further comprises a security routine stored in each of the first and the second inter-zone servers that determines whether the process control messages are authorized for transfer between the first and second process control networks, and that causes the communication routine to transfer process control messages that are determined to be authorized for transfer between the first and second process control networks.

15. The process control system of claim 14, wherein the authorization information of the process control messages is user information, and the security routine determines whether the process control messages are authorized for transfer between first and second process control networks by comparing the user information to a list of users authorized to transfer information between the first and second process control networks.

16. The process control system of claim 14, wherein the security routine determines whether the process control messages are authorized for transfer between the first and second process control networks after the process control messages are transferred from one of the first and second inter-zone servers to the other of the first and second inter-zone servers.

17. The process control system of claim 10, wherein the first process control network operates under a first alarm priority configuration and the second process control network operates under a second alarm priority configuration, one of the first and the second inter-zone servers having an alarm routine that converts alarm information in process control messages from a format compatible with the first alarm priority configuration to a format compatible with the second alarm priority configuration when the process control messages containing alarm information are transferred from the first process control network to the second process control network.

18. The process control system of claim 10, wherein the process control messages are condition monitoring messages.

19. The process control system of claim 10, wherein the first communication link is a shared local area network link.

20. The process control system of claim 10, wherein the first communication link is a satellite communication link.

21. The process control system of claim 10, wherein the first communication link is a cellular communication link.

22. The process control system of claim 10, wherein the first communication link is a telephone line communication link.

23. The process control system of claim 10, wherein the first communication link is a portable memory communication link.

24. The process control system of claim 10, wherein the first communication link is a wireless communication link.

25. The process control system of claim 10, wherein the first communication link is a wide area network link.

26. A local process control network in a process control system having a plurality of process control networks communicatively interconnected by communication links, the process control networks being able to transfer process control messages to each other via the communication links, the local process control network comprising:

a controller;

at least one device capable of performing process control functions;

a bus communicatively connecting the controller and the at least one device whereby the controller and the at least one device transmit process control messages on the bus; and

an inter-zone server connected to the bus and having a communication routine that uses at least one of the communication links to transfer process control messages between the controller and at least one device of the process control network, and a remote process control network of the process control system,

wherein the process control messages contain a device name for a receiving device to which the process control message is being transmitted, wherein the device name is defined for the receiving device within the process control system, and the communication routine of the inter-zone server uses the device name in the process control message to determine the process control network for the receiving device and transfers the process control message over one of the communication links to the remote process control network in response to determining that the receiving device is located in the remote process control network, and

wherein the controller and the at least one device operate under a first version of software and one of the remote process control networks operates under a second version of the software, the inter-zone server having a version control routine that converts process control messages from a format compatible with the first version of the software to a format compatible with the second version of the software when the process control messages are transferred to the one of the remote networks operating under the second version of the software.

27. The local process control network of claim 26, wherein each remote process control network of the process control system has a unique name defined for the remote process control network within the process control system, and the controller and at least one device transmit process control messages containing the unique names of the remote process control networks, the inter-zone server having a name routine that uses the unique names in the process control messages to cause the communication routine to use at least one of the communication links to transfer the process control messages containing the unique names to the corresponding remote process control networks.

28. The local process control network of claim 26, wherein the process control messages contain authorization information, and the inter-zone server having a security routine that determines whether the process control messages are authorized for transfer to the remote process control networks, and that causes the communication routine to transfer process control messages that are determined to be authorized for transfer to remote process control networks.

29. The local process control network of claim 28, wherein the authorization information of the process control messages is user information, and the security routine determines whether the process control messages are authorized for transfer to the remote process control networks by comparing the user information to a list of users authorized to transfer information to remote process control networks.

30. The local process control network of claim 26, wherein the remote process control networks transmit process control messages containing authorization information to the at least one device via the communication links, the inter-zone server having a security routine that determines whether the process control messages are authorized for receipt from the remote process control networks, and that causes the communication routine to transfer process control messages that are determined to be authorized for receipt to the at least one device via the bus.

31. The local process control network of claim 30, wherein the authorization information of the process control messages is user information, and the security routine determines whether the process control messages are authorized for receipt from the remote process control networks by comparing the user information to a list of users from whom process control messages from remote process control networks are authorized to be received.

32. The local process control network of claim 26, wherein one of the remote process control networks transmits process control messages in a format compatible with the second version of the software to the at least one device via the communication links, and the version control routine converts process control messages from the format compatible with the second version of the software to a format compatible with the first version of the software when the process control messages are received from the one of the remote networks operating under the second version of the software.

33. The local process control network of claim 26, wherein the controller and at least one device operate under a first alarm priority configuration and one of the remote process control networks operates under a second alarm priority configuration, the inter-zone server having an alarm routine that converts alarm information in process control messages from a format compatible with the first alarm priority configuration to a format compatible with the second alarm priority configuration when the process control messages containing alarm information are transferred from the local process control network to one of the remote process control networks.

34. The local process control network of claim 26, wherein the controller and at least one device are configured to use process control messages in a first verbal language and one of the remote process control networks is configured to use process control messages in a second verbal language, the inter-zone server having a language translation routine that converts process control messages in the first verbal language to process control messages in the second verbal language when process control messages are transferred to the one of the remote process control networks.

35. The local process control network of claim 26, wherein the controller and at least one device are configured to use process control messages in a first verbal language, and one of the remote process control networks is configured to use process control messages in a second verbal language and to transfer process control messages in the second verbal language to the local process control network via one of the communication links, the inter-zone server having a language translation routine that converts process control messages in the second verbal language to process control messages in the first verbal language when process control messages are received from the one of the remote process control networks.

36. The local process control network of claim 26, wherein the process control messages are condition monitoring messages.

37. An inter-zone server in a local process control network having a controller communicatively coupled by a bus with at least one device capable of performing process control functions, the process control network being part of a process control system having a plurality of remote process control networks communicatively interconnected by communication links, the remote process control networks being able to transfer process control messages to each other and the local process control network via the communication links, the inter-zone server comprising:

a first communication link that communicatively couples the inter-zone server to the local process control network for transferring and receiving process control messages;

a second communication link that communicatively couples the inter-zone server to one of the remote process control networks for transferring and receiving process control messages; and

a communication routine that uses the first and second communication links to transfer process control messages between the local process control network and the one of the remote process control networks,

wherein the process control messages contain a device named for a receiving device to which the process control message is being transmitted, wherein the device name is defined for the receiving device within the process control system, and the communication routine of the inter-zone server uses the device name in the process control message to determine the process control network for the receiving device and transfers the process control message over the second communication link to the remote process control network in response to determining that the receiving device is located in the remote process control network, and

wherein the controller and the at least one device operate under a first version of software and the one of the remote process control networks operates under a second version of the software, the inter-zone server further comprising a version control routine that converts process control messages from a format compatible with the first version of the software to a format compatible with the second version of the software when the process control messages are transferred to the one of the remote process control networks.

38. The inter-zone server of claim 37, wherein the one remote process control network has a unique name defined for the remote process control network within the process control system, and the controller and at least one device transmit process control messages containing the unique name of the one of the remote process control networks, the inter-zone server further comprising a name routine that uses the unique name in the process control messages to cause the communication routine to use the second communication link to transfer the process control messages containing the unique name to the one of the remote process control networks.

39. The inter-zone server of claim 37, wherein the process control messages contain authorization information, the inter-zone server further comprising a security routine that determines whether the process control messages are authorized between the controller and at least one device, and the one of the remote process control networks, and that causes the communication routine to transfer process control messages that are determined to be authorized for transfer.

40. The inter-zone server of claim 39, wherein the authorization information of the process control messages is user information, and the security routine determines whether the process control messages are authorized for transfer by comparing the user information to a list of users authorized to transfer process control messages between the controller and at least one device, and the one of the remote process control networks.

41. The inter-zone server of claim 37, wherein the one of the remote process control networks transmits process control messages in a format compatible with the second version of the software to the at least one device via the second communication link, and the version control routine converts process control messages from the format compatible with the second version of the software to a format compatible with the first version of the software when the process control messages are received from the one of the remote process control networks.

42. The inter-zone server of claim 37, wherein the controller and at least one device operate under a first alarm priority configuration and the one of the remote process control networks operates under a second alarm priority configuration, the inter-zone server further comprising an alarm routine that converts alarm information in process control messages from a format compatible with the first alarm priority configuration to a format compatible with the second alarm priority configuration when the process control messages containing alarm information are transferred from the local process control network to the one of the remote process control networks.

43. The inter-zone server of claim 37, wherein the controller and at least one device are configured to use process control messages in a first verbal language and the one of the remote process control networks is configured to use process control messages in a second verbal language, the inter-zone server further comprising a language translation routine that converts process control messages in the first verbal language to process control messages in the second verbal language when process control messages are transferred to the one of the remote process control networks.

44. The inter-zone server of claim 37, wherein the controller and at least one device are configured to use process control messages in a first verbal language, and the one of the remote process control networks is configured to use process control messages in a second verbal language, the inter-zone server further comprising a language translation routine that converts process control messages in the second verbal language to process control messages in the first verbal language when process control messages are received from the one of the remote process control networks.

45. The inter-zone server of claim 37, further comprising a third communications link that communicatively couples the inter-zone server to a second one of the remote process control networks for transferring and receiving process control messages, and wherein the communication routine uses the first and third communications links to transfer process control messages between the local process control network and the second one of the remote process control networks, and wherein the second and third communications links are used to transfer process control messages between the one of the remote process control networks and the second one of the remote process control networks.

46. The inter-zone server of claim 37, wherein the process control messages are condition monitoring messages.