Architecture for control systems

• US 7,908,020 B2
• Filed: 12/23/2005
• Issued: 03/15/2011
• Est. Priority Date: 12/24/2004
• Status: Expired due to Fees

• Current Assignee: Donald Pieronek
• Original Assignee: Donald Pieronek
• Inventors: Pieronek, Donald
• Primary Examiner(s): Patel; Ramesh B
• Assistant Examiner(s): STEVENS, THOMAS H
• Application Number:
  US11/317,318
• Publication Number:
  US 20060155387A1
• Time in Patent Office: 1,908 Days
• Field of Search: 700/19, 700/2, 712/14, 712/247, 726/22, 717/106, 717/108, 717/104, 714/52, 710/61, 710/62, 710/104, 710/113, 719/321
• US Class Current: 700/19
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/13101 Function block instance, only one function block exists, several instances
• CPC Class Codes: G05B 2219/13144 GUI graphical user interface, icon, function bloc editor, OI operator interface
• CPC Class Codes: G05B 2219/13148 Object oriented programming
• CPC Class Codes: G05B 2219/15012 Configuration software for networks
• CPC Class Codes: G05B 2219/23255 Object oriented programming, OOP
• CPC Class Codes: G05B 2219/25009 Profinet-I-O, producer-consumer mode
• CPC Class Codes: G05B 2219/25232 DCS, distributed control system, decentralised control unit

Abstract

An architecture for control systems including multiple control devices. The control devices include standardized software objects having functions, application programs for engaging these functions and thereby defining the operation of the control devices, and an engine for executing the application programs. The standardized software objects implement different types of internal functions for the control devices and feature reference numbering and function calls shared in common with the other software objects of the same type that may be on different control devices across said system. The software application programs include standardized instructions reflecting the reference numbering and function calls shared across the system by the said software objects whose functions are used in building the functionality of the control devices in the application programs.

Claims

1. A control system for a controlled process, the control system comprising:

a plurality of control devices reading electrical signals from sensors attached to elements of the controlled process or providing electrical signals from the control devices to actuators for actuating elements of the controlled process, where different types of control devices contain different electronic hardware where software drivers are written to control the different electronic hardware within the different types of control devices, the control devices further including control software held in computer readable memory and executable by the control devices which includes;

(a) a set of software objects that implement functions using a common software function call interface common to all the software objects where the common software function call interface defines two interface variables where no more than these two variables are used to pass data between all standardized software functions and having standardized function identifiers that are identical for the same standardized software function for the same software objects of a same object class on the different types of control devices across said control system, the software objects including hardware device driver objects having the common software function call interface in common with all other standardized software functions allowing direct manipulation of the electrical signals of the control devices unique electronic hardware and including other software objects not manipulating the electrical signals of the control devices different electronic hardware;

(b) a software application program including instructions comprising standardized function calls using identical said standardized function identifiers and said standardized common software function call interface to invoke standardized driver software functions of hardware device drivers objects and used to invoke software objects not manipulating the control devices electronic hardware, and

(c) an execution engine for running said software application program;

whereby a common interface is provided to all standardized software functions including the standardized driver software functions within the different types of control devices containing different electronic hardware and where said software application programs are thus portable across said different types of control devices in said control system.

2. The control system of claim 1, in which:

said software objects also have standardized property and class identifiers.

3. The control system of claim 1, in which:

each of said control devices further includes a virtual control bus including shared memory for passing values between said software objects where said virtual control bus provides a common internal software function call interface composed of no more than one thirty two bit or less variable and one eight bit or less variable that is in common with all standardized functions calls of all the standardized software object classes contained within the software application program where any standardized software function of any object class return values using the same two interface variables that are then used as input variables to any standardized software function of any other object class within portable application programs within said control device.

4. The control system of claim 3, wherein:

the software objects within the control devices having standardized network service identifiers to implement shared interpreted messaging services that have standard interface protocols in common with network service identifiers supported by the same object class within the different types of control devices across said control system, and in which said control devices further include;

(a) producer and consumer software communications objects that include standardized internal communications related software functions that utilize the common software function call interface as all other standardized function calls within the control device for implementing network communications within software application programs within the control devices that contain different electronic communications hardware where the software application programs are thus portable across different networks utilizing different network protocols, and

(b) a virtual configuration bus including shared memory on said control device for passing interpreted messages between the control devices used to directly interact with object classes via a network interface.

5. The control system of claim 1, in which:

said software objects include;

a branch software object and a relay software object.

6. The control system of claim 1, further including:

a tool device for monitoring, maintaining, and developing said software application programs for the control devices including the software objects that have standard identifiers in common with the software objects of the same object class within the different types of control devices across said control system.

7. The control system of claim 6, in which said tool device includes:

a display engine for interacting with said control devices for diagrammatically displaying hardware features, the software application program features, and networking features of the control devices.

8. The control system of claim 1 in which the hardware device driver objects include an input driver object reading a single electrical signal from the control devices electronic hardware or an output driver object outputting a single electrical signal to the control devices electronic hardware and anywhere in non-hardware device driver objects include a relay object providing logical functions of a virtual relay to monitor status of the single electrical signal or to set status of the single electrical signal from within an application program.

9. A process for operating a control system comprised of a plurality of control devices reading electrical signals of a control devices electronic hardware from sensors attached to elements of a controlled process or providing electrical signals to actuators for actuating elements of the controlled process, where different types of control devices contain different electronic hardware where software drivers are written to control unique electronic hardware within the different types of control devices, the control devices operating under control of different application programs, said process including steps of:

(a) provisioning said control devices with sets of standardized software objects that implement a standardized function call interface to all standardized software functions for the control device that can be combined in the different application programs to implement internal functionality of the control device and that have a standardized function call interface for all the standardized software objects where the standardized function call interface requires no more than two variables that are shared in common with all standardized software functions and identical function identifiers for the standardized software objects of a same object class contained within the different types of control devices across said control system the standardized software objects including hardware device driver objects having standardized software functions that utilize the standardized function call interface as all other standardized software functions allowing direct manipulation of the electrical signals of the control devices electronic hardware and including other software objects not manipulating the electrical signals of the control devices electronic hardware;

(b) defining application programs in terms of the standardized function call interface for engaging the standardized software functions of said standardized software objects that are based on said standardized function call interface and are compatible with the software objects of the same object class across different control devices containing different electronic hardware across said control system optionally including if and when the control device electronic hardware is updated; and

(c) configuring and monitoring said control devices using a tool device composed of a superset of said standardized software objects where the superset of standardized software objects contained within the tool device contain the standardized software functions of the control devices and additional software functions for the object classes utilized within the tool device to configure and monitor interconnection and execution of the standardized software functions within application programs within the control devices independent of the different electronic hardware within the different types of control devices that have standard interfaces in common with the standardized software objects on the different types of control devices across said control system and thus enable a single tool device to be utilized to configure and monitor the different types of control devices optionally sharing some of the application programs across the different types of control devices.

10. The process of claim 9, further including the step of:

simulating operation of one or more functional features of the control device using said tool device as an operating environment.

11. A control system for a controlled process, the control system comprising:

a) a plurality of control devices reading a control devices electronic hardware via electrical signals from sensors attached to elements of the controlled process or providing electrical signals from the control devices electronic hardware to actuators for actuating elements of the controlled process, where different types of control devices contain different electronic hardware where software drivers are written to control unique electronic hardware within the different types of control devices, the control devices further including control software held in computer readable memory and executable by the control devices which includes;

(i) a set of standardized software objects that implement different types of internal functions for the control device and that have a software function call interface common to all the standardized software objects where the software function call interface requires no more than two variables that are shared in common with all standardized software functions and standardized reference numbering in common with the standardized software objects of a same object class on the different types of control devices containing different electronic hardware across said control system including shared function call references, software objects including hardware device driver objects having the software function call interface in common with all standardized software functions allowing direct manipulation of the electrical signals of the control devices electronic hardware and including other software objects not manipulating the electrical signals of the control devices electronic hardware

(ii) a portable software application program including instructions implemented using standardized software functions based on said standardized reference numbering to the standardized software functions within said standardized software objects for engaging said internal functions optionally including if and when the control device electronic hardware is updated and thereby defining internal operation of the control device, where a control device may allow an end user to invoke the standardized software functions to add software application programs unique to process being controlled or where the end user may optionally change the software application programs that determine internal operational functionality of the control device containing unique electronic hardware when the internal operational functionality is inconsistent with needs of the controlled process,

(iii) an execution engine for running said software application program to read and provide electrical signals of the control devices electronic hardware from sensors and to actuators of the controlled process, and

b) a tool device for monitoring, maintaining, and developing said software application programs for the control devices including the standardized software objects that comprise a superset of said standardized software objects within one or more of the control devices and that have standardized reference numbering in common with the standardized software objects of the same object class within the different types of control devices across said control system.

12. The control system of claim 11, in which:

said standardized software objects also include standardized reference numbering for their shared classes and properties.

13. The control system of claim 11, in which:

said standardized software objects include;

a branch software object, a timer software object and a relay software object.

14. A control system, comprising:

a plurality of control devices having circuitry reading electrical signals of a control devices electronic hardware from sensors attached to elements of a controlled process or providing electrical signals from the control devices electronic hardware to actuators for actuating elements of a controlled process, where different types of control devices contain different electronic hardware where software drivers are written to control unique electronic hardware within the different types of control devices, the control devices further including control software held in computer readable memory and executable by the control devices which includes;

(a) a set of software functions for the control device including one or more standardized software functions having generic functionality useful in a variety of different control applications, the standardized software functions having a software function call interface in common with all standardized software objects where the software function call interface requires no more than two variables that are shared in common with all standardized software functions and having standardized function identifiers that are shared in common with other software functions of a same object class within the different types of control devices containing different types of electronic hardware across said control system, the software functions including hardware driver functions having the software function call interface in common with all the standardized software functions allowing direct manipulation of electrical signals of the control devices electronic hardware and including other software functions not manipulating electrical signals of the control devices electronic hardware;

(b) a software application program including instructions implemented using a standardized function call interface based on said standardized function identifiers to said standardized software functions for engaging said standardized software functions and thereby the software application programs define specific internal operational functionality of the control device optionally including if and when the control device electronic hardware is updated, where a control device may optionally allow an end user may use the standardized software functions to create software application programs for a controlled process or where the end user may change the specific internal operational functionality of a control device when it conflicts with needs of a controlled process, and

(c) an execution engine for running said software application program to read and provide electrical signals of the control devices electronic hardware from and to the controlled process;

whereby a common interface is provided to the standardized software functions within the control devices across said control devices containing different electronic hardware in said control system.

15. The control system of claim 14, in which:

said standardized software functions are included in the standardized software objects that also have standardized property and class identifiers.

16. The control system of claim 14, in which:

each of said control devices further includes a virtual control bus including shared memory for passing values between said standardized software objects.

17. The control system of claim 15, in which:

said standardized software objects include a branch software object and a relay software object.

18. The control system of claim 14, in which:

said software application program includes one or more of the hardware driver functions for controlling interactions with the control devices electronic hardware from within the software application program.

19. A control system, comprising:

a plurality of control devices having circuitry to collect data from sensors attached to elements of a controlled process or providing data to actuators for actuating elements of a controlled process, the control devices further including control software held in computer readable memory and executable by the control devices which includes;

(a) a set of software functions for the control device including one or more standardized software functions having generic functionality useful in a variety of different control applications the standardized software functions having a standardized software function call interface common to all standardized software objects and having standardized function identifiers that are identical among standardized software functions of a same object class contained within different types of control devices containing different electronic hardware across said control system, the standardized software functions including internal software functions allowing direct manipulation of electrical signals from sensor interface hardware or to actuator interface hardware via hardware device driver objects

(b) a software application program including instructions comprising standardized function calls based on said standardized function identifiers to said standardized software functions for engaging said standardized software functions and thereby defining a specific internal operational functionality of the control device optionally including if and when the control device electronic hardware is updated, where a control device may optionally allow an end user to use the standardized software functions to create software application programs for the controlled process or where the end user may change the specific internal operational functionality of a control device when it conflicts with needs of the controlled process, and

(c) an execution engine for running internal application programs to read from and write to electronic hardware components utilizing the standardized software functions of the hardware device driver objects to provide electrical signals of the control devices electronic hardware from sensors and to actuators of the controlled process;

whereby a common interface is provided to internal functions within the control devices across said control devices in said control system.

20. The control system of claim 19, in which:

said standardized software functions are included in the standardized software objects that also have standardized property and class identifiers, and said standardized software objects include a branch software object and a relay software object.