Apparatus, system, and method for integrating a wireless network with wired field devices in a process control system

• US 7,889,747 B2
• Filed: 05/31/2006
• Issued: 02/15/2011
• Est. Priority Date: 05/31/2006
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: McLaughlin, Paul F., Chernoguzov, Alexander, Hodson, William R., Samudrala, Prasad, Chen, Yu-Gene T.
• Primary Examiner(s): Ngo; Ricky
• Assistant Examiner(s): Kao; Wei-Po
• Application Number:
  US11/443,773
• Publication Number:
  US 20070280286A1
• Time in Patent Office: 1,721 Days
• Field of Search: 370/401, 370/402, 370/465, 370/466, 370/467
• US Class Current: 370/401
• CPC Class Codes: H04L 67/12 specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
• CPC Class Codes: H04L 69/08 Protocols for interworking; Protocol conversion
• CPC Class Codes: H04W 92/02 Inter-networking arrangements

Abstract

A system for integrating a wireless network with wired field devices includes a field unit that communicates with the wired field devices using a first wired field device protocol. A gateway wirelessly communicates with the field unit and communicates over a network using one or more second wired field device protocols. The gateway also converts between the first wired field device protocol and the one or more second wired field device protocols. The gateway could further permit access to the wired field devices by a component of the process control system (such as a process controller, asset management tool, or configuration tool) that does not support the first wired field device protocol. At least one of the field unit and the gateway could appear as a multiplexer or linking device to the component of the process control system, such as a HART multiplexer or a Foundation Fieldbus or Profibus linking device.

Claims

1. A system, comprising:

a plurality of field units, each field unit operable to communicate with an associated plurality of wired field devices in a process control system using one of a plurality of first wired field device protocols;

a gateway operable to wirelessly communicate with the field units, the gateway also operable to communicate using a plurality of second wired field device protocols, the gateway further operable to convert messages from the first wired field device protocol to at least one of the second wired field device protocols, the messages comprising information from two or more of the wired field devices and multiplexed by the field units; and

a marshalling panel that is separate from the gateway, the marshalling panel operable to communicate with the gateway and with a first component of the process control system, the marshalling panel operable to convert the messages from at least one of the second wired field device protocols to a third wired field device protocol used by the first component of the process control system;

wherein;

the gateway comprises a plurality of wired protocol objects and a plurality of mappings, the wired protocol objects representing multiple first application models that define how communications occur according to the first wired field device protocols, each mapping representing a map of one of the first application models to one of a plurality of second application models associated with one of the second wired field device protocols;

the first component of the process control system is operable to provide a control signal to one or more of the wired field devices via the marshalling panel, the gateway, and the field unit; and

the gateway and the field units are configured to operate as a distributed multiplexer under the first wired field device protocol, the gateway configured to further multiplex the multiplexed information from the field units.

2. The system of claim 1, wherein the gateway is further operable to permit access to the wired field devices by the first component of the process control system that views the wired field devices as a first type of field device and, at the same time, permit access to the wired field devices by a second component of the process control system that views the wired field devices as a second type of field device.

3. The system of claim 1, wherein the first component of the process control system comprises at least one of:

a process controller, an asset management tool, and a configuration tool.

4. The system of claim 1, wherein:

the first wired field device protocol used by the wired field devices comprises one of;

a Foundation Fieldbus protocol and a Profibus protocol;

the gateway is operable to cause the wired field devices to appear as Highway Addressable Remote Transducer (HART) field devices; and

a second component of the process control system comprises a component operable to use a HART protocol to communicate with the gateway.

5. The system of claim 4, wherein at least one of the mappings maps data from the wired field devices into a serial or Ethernet HART-compliant data stream such that the gateway appears as a HART multiplexer to the second component of the process control system and the field unit appears as a HART sub-multiplexer to the second component of the process control system.

6. The system of claim 1, wherein:

the first wired field device protocol used by the wired field devices comprises a Highway Addressable Remote Transducer (HART) protocol;

the gateway is operable to cause the wired field devices to appear as one of;

Foundation Fieldbus field devices and Profibus field devices; and

a second component of the process control system comprises a component operable to use one of;

a Foundation Fieldbus protocol and a Profibus protocol to communicate with the gateway.

7. An apparatus, comprising:

at least one memory operable to store;

a plurality of wired protocol objects representing multiple first application models that define how communications occur according to a plurality of first wired field device protocols; and

mapping information defining a plurality of mappings, wherein each mapping maps one of the first application models associated with one of the first wired field device protocols to one of a plurality of second application models associated with one of a plurality of second wired field device protocols; and

at least one processor operable to;

receive first information transmitted wirelessly from each of a plurality of field units, each field unit operable to communicate with an associated plurality of wired field devices in a process control system using one of the first wired field device protocols, wherein the first information comprises information from two or more of the wired field devices and multiplexed by the field units, the information from the two or more wired field devices comprising scan information received in response to scans of the field devices by the field units;

convert the first information into second information associated with at least one of the second wired field device protocols using at least some of the mapping information; and

communicate the second information using at least one of the second wired field device protocols to a marshalling panel for delivery to a first component of the process control system, the marshalling panel separate from the apparatus and operable to convert the second information associated with the at least one second wired field device protocol into third information associated with a third wired field device protocol used by the first component of the process control system;

wherein the gateway and the field units are configured to operate as a distributed multiplexer under the first wired field device protocol, the gateway configured to further multiplex the multiplexed information from the field units.

8. The apparatus of claim 7, wherein the at least one processor is further operable to:

receive third information associated with at least one of the second wired field device protocols;

convert the third information associated with at least one of the second wired field device protocols into fourth information associated with at least one of the first wired field device protocols using at least some of the mapping information; and

initiate wireless communication of the fourth information to at least one of the field units for delivery to one or more of the wired field devices.

9. The apparatus of claim 7, further comprising at least one interface operable to communicate over a network, the at least one interface comprising at least one of:

an Ethernet interface and a serial interface.

10. The apparatus of claim 7, wherein the at least one processor is operable to permit access to the wired field devices by the first component of the process control system that views the wired field devices as a first type of field device and, at the same time, permit access to the wired field devices by a second component of the process control system that views the wired field devices as a second type of field device.

11. The apparatus of claim 10, wherein the first wired field device protocol used by each plurality of wired field devices, the second wired field device protocol used by the first component of the process control system, and the second wired field device protocol used by the second component of the process control system are different from one another.

12. The apparatus of claim 10, wherein:

the first and second components comprise at least one of;

a process controller, an asset management tool, and a configuration tool; and

the wired field devices comprise at least one of;

one or more sensors and one or more actuators.

13. The apparatus of claim 7, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises one of;

a Foundation Fieldbus protocol and a Profibus protocol;

the apparatus is operable to cause the wired field devices to appear as Highway Addressable Remote Transducer (HART) field devices; and

a second component of the process control system comprises a component operable to use a HART protocol to communicate with the apparatus.

14. The apparatus of claim 7, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises a Highway Addressable Remote Transducer (HART) protocol;

the apparatus is operable to cause the wired field devices to appear as one of;

Foundation Fieldbus field devices and Profibus field devices; and

a second component of the process control system comprises a component operable to use one of;

a Foundation Fieldbus protocol and a Profibus protocol to communicate with the apparatus.

15. A method, comprising:

storing a plurality of wired protocol objects in a gateway, the wired protocol objects representing multiple first application models that define how communications occur according to a plurality of first wired field device protocols;

storing a plurality of mappings in the gateway, wherein each mapping maps one of the first application models associated with one of the first wired field device protocols to one of a plurality of second application models associated with one of a plurality of second wired field device protocols;

wirelessly receiving first information from each of a plurality of field units at the gateway, each field unit communicating with an associated plurality of wired field devices in a process control system using at least one of the first wired field device protocols , the first information comprising information from two or more of the wired field devices and multiplexed by the field units;

converting in the gateway the first information into second information associated with at least one of the second wired field device protocols using at least one of the mappings; and

communicating the second information from the gateway using the at least one of the second wired field device protocols to a marshalling panel for delivery to a first component of the process control system, the marshalling panel separate from the gateway and converting the second information associated with the at least one second wired field device protocol into third information associated with a third wired field device protocol used by the first component of the process control system;

wherein the gateway and the field units are configured to operate as a distributed multiplexer under the first wired field device protocol, the gateway configured to further multiplex the multiplexed information from the field units.

16. The method of claim 15, wherein the plurality of first wired field device protocols and the plurality of second wired field device protocols have at least one common wired field device protocol.

17. The method of claim 15, wherein the first component comprises a process controller.

18. The method of claim 15, further comprising:

causing the wired field devices to appear as if the wired field devices are coupled to the distributed multiplexer and to a linking device at the same time.

19. The method of claim 15, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises one of;

a Foundation Fieldbus protocol and a Profibus protocol;

the method further comprises causing the wired field devices to appear as Highway Addressable Remote Transducer (HART) field devices; and

a second component of the process control system comprises a component operable to use a HART protocol to communicate with the wired field devices.

20. The method of claim 15, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises a Highway Addressable Remote Transducer (HART) protocol;

the method further comprises causing the wired field devices to appear as one of;

Foundation Fieldbus field devices and Profibus field devices; and

a second component of the process control system comprises a component operable to use one of;

a Foundation Fieldbus protocol and a Profibus protocol to communicate with the wired field devices.

21. A tangible computer readable storage medium embodying a computer program, the computer program comprising computer readable program code for:

storing a plurality of wired protocol objects representing multiple first application models that define how communications occur according to a plurality of first wired field device protocols;

storing a plurality of mappings, wherein each mapping maps one of the first application models associated with one of the first wired field device protocols to one of a plurality of second application models associated with one of a plurality of second wired field device protocols;

receiving first information transmitted wirelessly from each of a plurality of field units to a gateway, each field unit configured to communicate with an associated plurality of wired field devices using one of the first wired field device protocols, the first information comprising information from two or more of the wired field devices and multiplexed by the field units;

converting the first information into second information associated with at least one of the second wired field device protocols using at least one of the mappings;

initiating communication of the second information using at least one of the second wired field device protocols to a marshalling panel for delivery to a first component of the process control system, the marshalling panel separate from the gateway and operable to convert the second information associated with the at least one second wired field device protocol into third information associated with a third wired field device protocol used by the first component of the process control system; and

causing the gateway to operate as a distributed multiplexer along with the plurality of field units under the first wired field device protocol and to further multiplex the multiplexed information from the field units.

22. The computer readable storage medium of claim 21, further comprising computer readable program code for:

receiving third information using at least one of the second wired field device protocols;

converting the third information into fourth information associated with at least one of the first wired field device protocols; and

initiating wireless transmission of the fourth information to at least one of the field units for delivery to one or more of the wired field devices using at least one of the first wired field device protocols.

23. The computer readable storage medium of claim 21, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises one of;

a Foundation Fieldbus protocol and a Profibus protocol;

the computer program when executed causes the wired field devices to appear as Highway Addressable Remote Transducer (HART) field devices; and

a second component of the process control system comprises a component operable to use a HART protocol to communicate with the gateway.

24. The computer readable storage medium of claim 21, wherein:

the first wired field device protocol used by each plurality of wired field devices comprises a Highway Addressable Remote Transducer (HART) protocol;

the computer program when executed causes the wired field devices to appear as one of;

Foundation Fieldbus field devices and Profibus field devices; and

a second component of the process control system comprises a component operable to use one of;

a Foundation Fieldbus protocol and a Profibus protocol to communicate with the gateway.