Wireless industrial control user interface

• US 7,668,605 B2
• Filed: 10/26/2005
• Issued: 02/23/2010
• Est. Priority Date: 10/26/2005
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Knutsen, Neil W., Braun, Scott D., Weingarth, Christine E., Steinweg, Calvin C.
• Primary Examiner(s): Hartman, Jr.; Ronald D
• Application Number:
  US11/259,441
• Publication Number:
  US 20070093921A1
• Time in Patent Office: 1,581 Days
• Field of Search: 700/17, 700/83
• US Class Current: 700/17
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31174 Load, use different protocols, formats, emulators for different systems
• CPC Class Codes: G05B 2219/31195 WAP wireless application protocol, wireless web application
• CPC Class Codes: G05B 2219/36159 Detachable or portable programming unit, display, pc, pda
• CPC Class Codes: G06F 21/45 Structures or tools for the administration of authentication
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An industrial control system includes a motor drive, a wireless interface module, and a wireless user interface. The motor drive has at least a first port. The wireless interface module is coupled to the first port of the motor drive. The wireless user interface is operable to connect to the wireless interface module and establish a first connection through the wireless interface module to access the motor drive. A user interface operable to connect to a device within an industrial control system includes a display and a processing unit operable to establish a connection with the device and display an image representative of the device on the display responsive to establishing the connection.

Claims

1. A system for communicating with a motor drive comprising:

a motor drive configured to control operation of a motor and having a first port;

a wireless interface module coupled to the first port of the motor drive; and

a wireless user interface comprised of;

a display;

a processing unit; and

a memory having stored therein a plurality of software applications and a configuration mask defining which of the software applications a user may access;

wherein the wireless user interface is configured to communicate with the wireless interface module to establish a connection to the motor drive through the wireless interface module and receive data directly from the motor drive and display the data received from the motor drive on the display;

wherein the data received directly from the motor drive includes at least one of a representative image, an actual image of the motor drive, a name of the motor drive, and a type of the motor drive and wherein the wireless user interface is configured to display at least two of the representative image and the actual image of the motor drive, the name of the motor drive, and the type of the motor drive on the display simultaneously.

2. The system of claim 1 wherein the connection to the motor drive through the wireless interface module is a point-to-point connection.

3. The system of claim 2 wherein the point-to-point connection bypasses a human-machine interface (HMI).

4. The system of claim 2 wherein the point-to-point connection includes a serial communications link between the wireless user interface and the motor drive through the wireless interface module.

5. The system of claim 2 wherein the point-to-point connection is an exclusive communications link between the wireless user interface and the motor drive through the wireless interface module.

6. The system of claim 5 wherein, upon establishing the exclusive communications link, the wireless interface module is further configured to preclude another wireless user interface from connecting to the motor drive unit through the wireless interface module.

7. The system of claim 1 wherein the data received directly from the motor drive further includes at least one of a configuration of the motor drive and diagnostic information about the motor drive and wherein the screen is configured to display the at least one of the configuration of the motor drive and diagnostic information about the motor drive.

8. The system of claim 7 wherein the diagnostic information includes a current run time of the motor drive and power cycles of the motor drive.

9. The system of claim 7 wherein the wireless user interface includes an upload/download tool configured to run from the wireless user interface to selectively store configuration data of the motor drive and selectively replace configuration data stored on the motor drive unit with configuration data stored on the wireless user interface by communicating with the motor drive through the wireless interface module.

10. The system of claim 9 wherein the configuration data includes operational parameters, defined communication links, process display settings, and stored parameter sets.

11. The system of claim 1 wherein the wireless user interface includes a flash update tool configured to run from the wireless user interface to upgrade a firmware of the motor drive by transferring a flash update data file stored on the wireless user interface to the motor drive through the wireless interface module.

12. The system of claim 11 wherein the flash update tool includes a plurality of flash update files and wherein the wireless user interface is configured to determine if any of the stored flash update files are applicable to the motor drive unit to which the wireless user interface is connected and display only the flash update files applicable to the motor drive unit in an available update field on the display of the wireless user interface.

13. The system of claim 1 wherein the wireless user interface is configured to communicate with the wireless interface module using a first communications protocol and to communicate with the motor drive using a second communications protocol different from the first communications protocol, and wherein messages formatted using the second communications protocol are encapsulated by the first communications protocol for communication between the wireless user interface and the wireless interface module.

14. The system of claim 1 further comprising at least one peripheral associated with the motor drive and wherein the wireless user interface configured to further communicate with the wireless interface module to establish a connection to access the peripheral.

15. The system of claim 14 wherein the connection to access the peripheral bypasses an HMI.

16. The system of claim 14 wherein the screen of the wireless user interface is further configured to display at least one of a representative image and an actual image of the peripheral, a name of the peripheral, and a type of the peripheral simultaneously in screen of the wireless interface module upon accessing the peripheral.

17. The system of claim 16 wherein the wireless user interface is further configured to display at least one of a configuration of the peripheral and diagnostic information about the peripheral in the screen.

18. The system of claim 1 further comprising:

a communication network;

a communication module coupled to a second port of the motor drive and in communications with the communication network;

at least one device coupled to the communication network; and

an HMI coupled to the communication network and configured to communicate with the motor drive over the communications network;

wherein the wireless user interface is configured to establish a second connection through the wireless interface module and the communication module to the at least one device coupled to the communications network.

19. The system of claim 18 wherein the second connection through the wireless interface module and the communication module bypasses the HMI.

20. An industrial automation system comprising:

a plurality of motor drives configured to control operation of respective motors and having at least a first network communications port configured to receive a wired network connection;

a plurality of respective peripherals connected to the motor drives;

a plurality of respective wireless interface modules coupled to the first network communications port of each motor drive; and

a wireless user interface configured to connect to a selected wireless interface module to establish a direct connection to at least one of the motor drive having the selected wireless interface module and the peripheral connected to the motor drive through the wireless interface module and to receive data directly from at least one of the motor drive and the peripheral;

wherein the wireless user interface is further configured to display at least one of a representative image, an actual image of the peripheral, a name of the peripheral, and a type of the peripheral simultaneously when connected to the peripheral.

21. The system of claim 20 wherein the direct connection to at least one of the motor drive and the peripheral bypasses an HMI.

22. The system of claim 20 wherein the direct connection includes a serial communications link between the wireless user interface and the at least one of the motor drive and the peripheral through the wireless interface module.

23. The system of claim 22 wherein the serial connection forms an exclusive communications link between the wireless user interface and the motor drive through the wireless interface module.

24. The system of claim 20 wherein the data received directly from at least one of the motor drive and the peripheral includes at least one of a representative image and an actual image of one of the motor drive and the peripheral, a name associated with the image, and a device type associated with the image and wherein the wireless user interface includes a display configured to display the data received directly from at least one of the motor drive and the peripheral simultaneously in a common screen.

25. A method of communicating with a motor drive comprising:

providing a motor drive having a wireless interface module;

providing a wireless user interface configured to connect to the wireless interface module to establish a connection through the wireless interface module to access data stored in the motor drive;

providing a flash update tool configured to run from the wireless user interface to upgrade a firmware of the motor drive by transferring a flash update data file stored on the wireless user interface to the motor drive through the wireless interface module; and

displaying in a screen of the wireless user interface an image of the motor drive and a device name differentiating the motor drive from another motor drive.

26. The method of claim 25 wherein the wireless interface module is further configured to establish a direct and exclusive connection between the wireless user interface and the at least one of the motor drive.

27. An industrial control system for communicating with a motor drive comprising:

a motor drive configured to control operation of a motor and having a first and second port;

a wireless interface module coupled to the first port of the motor drive;

a wireless user interface configured to communicate with the wireless interface module to establish a first connection to the motor drive through the wireless interface module and receive data directly from the motor drive and display the data received from the motor drive on a screen included in the wireless user interface;

a communication network;

a communication module coupled to the second port of the motor drive and in communication with the communication network;

at least one device coupled to the communication network; and

an HMI coupled to the communication network and configured to communicate with the motor drive over the communications network;

wherein the motor drive includes at least one of a representative image, an actual image of the motor drive, a name of the motor drive, and a type of the motor drive, wherein the screen is configured to display at least one of the representative image and the actual image of the motor drive, the name of the motor drive, and the type of the motor drive in the screen simultaneously, and wherein the wireless user interface is further configured to establish a second connection through the wireless interface module and the communication module to the at least one device coupled to the communications network.