Simulation system for multi-node process control systems

• US 7,392,165 B2
• Filed: 10/21/2002
• Issued: 06/24/2008
• Est. Priority Date: 10/21/2002
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Lucas, Michael, Nixon, Mark, Stevenson, Dennis, Blevins, Terrence
• Primary Examiner(s): Rodriguez; Paul
• Assistant Examiner(s): PIERRE LOUIS, ANDRE
• Application Number:
  US10/274,562
• Publication Number:
  US 20040078182A1
• Time in Patent Office: 2,073 Days
• Field of Search: 703/7, 700/90, 700/19, 700/51, 700/80
• US Class Current: 703/7
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G06F 11/261 by simulating additional hardware, e.g. fault simulation

Abstract

A simulation system attaches to a configuration database for one or more fully configured nodes of a process control system and copies the modules within those nodes into one or more simulation computers as simulation modules. The simulation system includes an algorithm that automatically creates a reference parameter module for each of the copied nodes that stores a reference parameter for each of the inputs, outputs or other references to signals external to the nodes. In the case of the Fieldbus function blocks, the simulation system automatically creates a function block within the simulation workstation in the protocol of the controller node which mimics the operation of the Fieldbus function block, and then creates the simulation system having those mimicked Fieldbus function blocks operating as if they had originally been configured to be in the controller being simulated, instead of within a field device external to the controller.

Claims

1. A method of creating a simulation system for simulating the operation of one or more nodes of a process control system having a plurality communicatively interconnected modules at each of the one or more nodes and a configuration for each of the one or more nodes stored in a configuration database, the configuration for each of the one or more nodes defining a set of modules to be executed on one or more computer devices within a node and communication connections between the modules, wherein each of the modules when executed at the node performs a process control related function, the method comprising;

specifying at least one node of the process control system for which to create a simulation instance;

accessing the configuration database to obtain copies of the modules within the configuration of the at least one specified node of the process control system;

storing the copies of the modules within a simulation computer; and

automatically converting the copied modules into simulation modules to create the simulation instance having a plurality of communicatively interconnected simulation modules.

2. The method of creating a simulation system of claim 1, wherein at least one of the copied modules is in a controller protocol and further including determining from the configuration database, the existence of a second module using a different protocol than the controller protocol, creating a second simulation module in the controller protocol for the second module and communicatively interconnecting second simulation module with the interconnected simulation modules.

3. The method of creating a simulation system of claim 2, wherein the second module is a function block.

4. The method of creating a simulation system of claim 2, wherein determining includes determining the existence of a Fieldbus module.

5. The method of creating a simulation system of claim 2, wherein creating a second simulation module includes using a list that specifies a conversion between a particular module within the different protocol and a particular module within the controller protocol.

6. The method of creating a simulation system of claim 5, wherein using a list includes using a list that specifies parameter conversions between the particular module within the different protocol and the particular module within the controller protocol.

7. The method of creating a simulation system of claim 2, wherein at least one of the copied modules includes an external reference parameter and further including creating an external reference parameter module to store the external reference parameter in the simulation computer.

8. The method of creating a simulation system of claim 7, wherein creating the external reference parameter module includes creating a single external reference parameter module to hold multiple external reference parameters for one of the specified nodes.

9. The method of creating a simulation system of claim 7, wherein creating the external reference parameter module includes creating a single external reference parameter module to hold all of the external reference parameters for one of the specified nodes.

10. The method of creating a simulation system of claim 1, wherein at least one of the copied modules includes an external reference parameter and further including creating an external reference parameter module to store the external reference parameter in the simulation computer.

11. The method of creating a simulation system of claim 10, wherein creating the external reference parameter module includes creating a single external reference parameter module to hold multiple external reference parameters for one of the specified nodes.

12. The method of creating a simulation system of claim 10, wherein creating the external reference parameter module includes creating a single external reference parameter module to hold all of the external reference parameters for one of the specified nodes.

13. The method of creating a simulation system of claim 1, further including disabling an input or output status indication associated with at least one of the simulation modules.

14. The method of creating a simulation system of claim 13, wherein disabling includes disabling the input or output status indication associated with an output function block.

15. The method of creating a simulation system of claim 13, wherein disabling includes disabling the input or output status indication associated with an input function block.

16. The method of creating a simulation system of claim 1, wherein the modules within the process control system include redundancy capabilities and further including creating the simulation modules to include redundancy capabilities and using the redundancy capabilities of the simulation modules to capture a snapshot of the simulation system during execution of the simulation system.

17. The method of creating a simulation system of claim 16, wherein using the redundancy capabilities of the simulation modules includes tying redundancy signals created by the simulation modules to particular memory locations within the simulation computer and copying the contents of the particular memory locations within the simulation computer to a snapshot file to obtain a snapshot of the simulation system.

18. A method of obtaining a snapshot of a simulation system for a process control system having modules with redundancy capabilities that create redundancy signals to be sent to redundant modules within the process control system, wherein each of the modules performs one or more control or communication functions, the method comprising:

creating a simulation system as a plurality of communicatively interconnected simulation modules which create redundancy signals for parameters thereof;

sending the redundancy signals of the communicatively interconnected simulation modules within the simulation system to be stored in dedicated memory locations in a simulation computer during operation of the simulation system; and

storing a snapshot of the simulation system at a particular time by;

halting operation of the simulation system at the particular time;

copying the contents of the dedicated memory locations into a snapshot file; and

continuing operation of the simulation system.

19. The method of obtaining a snapshot of a simulation system of claim 18, further including restoring the simulation system to a previous condition by halting operation of the simulation system, accessing the snapshot file, copying the contents of the snapshot file into the communicatively interconnected simulation modules, and then continuing operation of the simulation system.

20. The method of obtaining a snapshot of a simulation system of claim 18, including automatically and periodically performing the steps associated with storing a snapshot of the simulation system during operation of the simulation system.

21. A simulation creation system for creating a simulation instance to simulate the operation of one or more nodes of a process control system having a plurality communicatively interconnected modules at each of the one or more nodes and a configuration for each of the one or more nodes stored in a configuration database, the configuration for each of the one or more nodes defining a set of modules to be executed on one or more computer devices within a node and communication connections between the modules, wherein each of the modules when executed at the node performs a process control related function, the simulation creation system comprising;

a processor;

a computer readable memory;

a first routine stored on the computer readable memory to be executed on the processor to enable a user to specify at least one node of the process control system for which to create a simulation instance; and

a second routine stored on the computer readable memory to be executed on the processor to create a simulation instance for the specified node by;

accessing the configuration database to obtain copies of the modules within the configuration of the specified node;

storing the copies of the modules within a simulation memory; and

automatically converting the copied modules into simulation modules to create the simulation instance having a plurality of communicatively interconnected simulation modules.

22. The simulation creation system of claim 21, wherein at least one of the copied modules is in a controller protocol and wherein the second routine determines from the configuration database, the existence of a second module using a different protocol than the controller protocol, creates a second simulation module in the controller protocol for the second module and communicatively interconnects the second simulation module with the communicatively interconnected simulation modules.

23. The simulation creation system of claim 22, further including a list stored on the computer readable memory that specifies a conversion between a particular module within the different protocol and a particular module within the controller protocol and wherein the second routine uses the list to create the second simulation module in the controller protocol.

24. The simulation creation system of claim 23, wherein the list further specifies parameter conversions between the particular module within the different protocol and the particular module within the controller protocol.

25. The simulation creation system of claim 21, wherein at least one of the copied modules includes an external reference parameter and wherein the second routine creates an external reference parameter module to store the external reference parameter in the computer readable memory.

26. The simulation creation system of claim 25, wherein the second routine creates a single external reference parameter module to hold all of the external reference parameters for one of the specified nodes.

27. The simulation creation system of claim 21, wherein the second routine disables an input or output status indication on at least one of the simulation modules.

28. The simulation creation system of claim 27, wherein the second routine disables the input or output status indication on an input function block.

29. The simulation creation system of claim 21, wherein the modules within the process control system include redundancy capabilities and wherein the second routine creates the simulation modules to include redundancy capabilities and further including a third routine stored on the computer readable memory to be executed on the processor to use the redundancy capabilities of the simulation modules to capture a snapshot of the simulation system during execution of the simulation system.

30. The simulation creation system of claim 29, wherein the second routine ties the redundancy signals created by the simulation modules to particular memory locations within the simulation memory and the third routine copies the contents of the particular memory locations within the simulation memory to a snapshot file to obtain a snapshot of the simulation system.