Apparatus and method for wireless process control

• US 7,424,328 B2
• Filed: 01/03/2006
• Issued: 09/09/2008
• Est. Priority Date: 01/03/2006
• Status: Expired due to Fees

• Current Assignee: Industrial Telemetry Incorporated
• Original Assignee: Industrial Telemetry Incorporated
• Inventors: De Silvio, Louis F.
• Primary Examiner(s): Pham; Thomas K
• Application Number:
  US11/327,828
• Publication Number:
  US 20070156253A1
• Time in Patent Office: 980 Days
• Field of Search: 700/18, 700/23, 700/65, 700/86, 700/87, 700/89, 700/181, 717/136, 717/140
• US Class Current: 700/18
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/15117 Radio link, wireless

Abstract

An apparatus includes a programmable logic controller capable of receiving input data from and/or providing output data to at least one device in a process control system. The programmable logic controller is also capable of executing compiled code. The apparatus also includes a memory capable of storing source code corresponding to the compiled code. In addition, the apparatus includes a processor capable of storing the source code in the memory. The apparatus may further include a wireless radio capable of communicating over a wireless network. In particular embodiments, the programmable logic controller and the processor may form a single functional unit. In other embodiments, the processor and memory may operate in place of the programmable logic controller.

Claims

1. An apparatus for wireless process control, comprising:

a programmable logic controller capable of at least one of;

receiving first input data from at least one device in a process control system and providing output data to the at least one device in the process control system, the programmable logic controller also capable of executing compiled code, the process control system associated with a process;

a wireless radio capable of communicating over a wireless network;

a memory capable of storing source code corresponding to the compiled code; and

a processor capable of receiving second input data associated with the process and providing the second input data to the wireless radio for transmission over the wireless network without placing a processing burden on the programmable logic controller;

wherein the second input data is received by the wireless radio over the wireless network, and the processor is capable of providing the second input data to the wireless radio for transmission to provide a repeater function in the wireless network.

2. The apparatus of claim 1, wherein the processor is further capable of:

retrieving the source code from the memory; and

providing the source code to the wireless radio for transmission over the wireless network.

3. The apparatus of claim 1, wherein the processor is further capable of:

receiving a poll for information about the source code stored in the memory; and

providing the information to the wireless radio for transmission over the wireless network.

4. The apparatus of claim 1, wherein the processor is further capable of:

identifying a destination associated with the first input data using a mapping, the mapping associated with an input used to receive the first input data; and

providing the first input data to the wireless radio for transmission to the destination via the wireless network.

5. The apparatus of claim 1, wherein the processor is further capable of:

receiving third input data from the wireless radio, the third input data received over the wireless network; and

at least one of;

providing the third input data to the programmable logic controller, the programmable logic controller capable of generating the output data based on the third input data, the output data for controlling one or more of the at least one device; and

generating second output data based on the third input data, the second output data for controlling one or more of the at least one device.

6. The apparatus of claim 1 wherein the wireless radio comprises a wireless peer-to-peer, multipoint-to-multipoint radio capable of communicating over a wireless mesh network.

7. The apparatus of claim 1, wherein the programmable logic controller and the processor form a single functional unit.

8. The apparatus of claim 1, wherein:

the processor is coupled to a plurality of analog outputs and is capable of generating a plurality of analog output signals;

the programmable logic controller is coupled to a plurality of analog inputs and is capable of receiving a plurality of analog input signals; and

the programmable logic controller is coupled to a plurality of digital inputs/outputs and is capable of at least one of;

generating one or more digital output signals and receiving one or more digital input signals.

9. The apparatus of claim 1, wherein the at least one device in the process control system comprises one or more of:

a sensor capable of measuring one or more characteristics in the process control system;

an actuator capable of initiating one or more physical actions in the process control system; and

a processing element capable of performing one or more physical actions in the process control system.

10. The apparatus of claim 1, wherein:

the programmable logic controller comprises a single chip;

the memory comprises a Flash memory; and

the processor comprises a microcontroller.

11. A method for wireless process control, comprising:

executing compiled code at a programmable logic controller, the programmable logic controller forming part of or associated with a first controller in a process control system, the process control system associated with a process being controlled;

storing source code corresponding to the compiled code in a memory of the first controller; and

receiving input data associated with the process at a processor in the first controller and wirelessly communicating the input data to a second controller over a wireless network without placing a processing burden on the programmable logic controller, the controllers capable of controlling at least one device in the process control system;

wherein the input data is received over the wireless network and is wirelessly communicated to the second controller to provide a repeater function in the wireless network.

12. The method of claim 11, wherein storing the source code comprises providing the source code to processor in the first controller, the processor capable of storing the source code in the memory.

13. The method of claim 11, further comprising:

retrieving the source code from the memory; and

wirelessly communicating the source code over the wireless network.

14. The method of claim 11, further comprising:

receiving a poll for information about the source code stored in the memory; and

wirelessly communicating the information over the wireless network.

15. The method of claim 11, further comprising:

receiving second input data through an input of the first controller;

identifying a destination associated with the second input data using a mapping, the mapping associated with the input of the first controller and a radio and an input or output of the second controller; and

addressing data packets containing the second input data with an address associated with the identified destination.

16. The method of claim 11, further comprising:

receiving second input data from the second controller; and

generating output data based on the second input data, the output data for controlling one or more of the at least one device.

17. The method of claim 11, wherein wirelessly communicating the input data comprises using a wireless peer-to-peer, multipoint-to-multipoint radio capable of communicating over a wireless mesh network.

18. The method of claim 11, wherein the at least one device in the process control system comprises one or more of:

a sensor capable of measuring one or more characteristics in the process control system;

an actuator capable of initiating one or more physical actions in the process control system; and

a processing element capable of performing one or more physical actions in the process control system.

19. The method of claim 11, wherein the programmable logic controller forms part of the processor in the first controller.

20. A system for wireless process control, comprising:

a plurality of devices associated with a process and capable of one or more of;

measuring one or more characteristics in the system, initiating one or more physical actions in the system, and performing one or more physical actions in the system; and

a plurality of controllers coupled to the plurality of devices, each of at least one of the controllers comprising;

a programmable logic controller capable of at least one of;

receiving input data from at least one of the devices and providing output data to at least one of the devices, the programmable logic controller also capable of executing compiled code;

a memory capable of storing source code corresponding to the compiled code;

a wireless radio capable of communicating with at least one other of the controllers over a wireless network; and

a processor capable of receiving second input data associated with the process and providing the second input data to the wireless radio for transmission to at least one other of the controllers over the wireless network without placing a processing burden on the programmable logic controller;

wherein the second input data is received over the wireless network and the processor is capable of providing the second input data to the wireless radio for transmission to provide a repeater function in the wireless network.

21. The system of claim 20, further comprising a workstation capable of at least one of:

polling one or more of the controllers to identify the source code stored in the memory of the one or more controllers; and

retrieving the source code stored in the memory of one or more of the controllers.

22. The system of claim 21, wherein the workstation is further capable of:

allowing a user to alter mappings between inputs and outputs of the controllers.

23. An apparatus, comprising:

a processor capable of communicating with an external programmable logic controller, the programmable logic controller capable of at least one of;

receiving input data from at least one device in a process control system and providing output data to the at least one device in the process control system, the programmable logic controller also capable of executing compiled code, the process control system associated with a process being controlled;

a wireless radio capable of communicating over a wireless network; and

a memory capable of storing source code corresponding to the compiled code;

wherein the processor is further capable of receiving second input data associated with the process and providing the second input data to the wireless radio for transmission over the wireless network without placing a processing burden on the programmable logic controller; and

wherein the second input data is received over the wireless network and the processor is capable of providing the second input data to the wireless radio for transmission to provide a repeater function in the wireless network.