Wireless architecture and support for process control systems

• US 8,144,622 B2
• Filed: 10/13/2008
• Issued: 03/27/2012
• Est. Priority Date: 06/18/2003
• Status: Expired due to Fees

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Nelson, Joe, Shepard, John R.
• Primary Examiner(s): Tran, Cong
• Application Number:
  US12/250,410
• Publication Number:
  US 20090097415A1
• Time in Patent Office: 1,261 Days
• Field of Search: 370/254, 370/328, 370/401, 370/466, 370/467, 455/428, 455/450
• US Class Current: 370/254
• CPC Class Codes: G05B 2219/21079 Allocate at start up also to each controlled device a code for the master
• CPC Class Codes: G05B 2219/25061 Configuration stored in central database
• CPC Class Codes: G05B 2219/25101 Detect connected module, load corresponding parameters, variables into module
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31123 Multi mode network controller, monitor, control, configuration, maintenance
• CPC Class Codes: G05B 2219/31151 Lan local area network
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: H04W 40/24 Connectivity information management, e.g. connectivity discovery or connectivity update
• CPC Class Codes: H04W 76/14 Direct-mode setup
• CPC Class Codes: H04W 8/20 Transfer of user or subscriber data
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A wireless communication system for use in a process environment uses mesh and possibly a combination of mesh and point-to-point communications to produce a wireless communication network that can be easily set up, configured, changed and monitored, thereby making a wireless communication network that is less expensive, and more robust and reliable. The wireless communication system allows virtual communication paths to be established and used within the process control system in a manner that is independent of the manner in which the wireless signals are sent between different wireless transmitting and receiving devices within the process plant, to thereby operate in a manner that is independent of the specific messages or virtual communication paths within the process plant. Still further, communication analysis tools are provided to enable a user or operator to view the operation of the wireless communication network to thereby analyze the ongoing operation of the wireless communications within the wireless communication network.

Claims

1. A method for controlling a process using a wireless communications network, the method comprising:

receiving, at a field node of the process, field data from at least one field device of the process;

transmitting the field data wirelessly from the field node to a base node of the process using a first wireless communication protocol;

converting the field data from the first wireless communication protocol to a different wireless communication protocol;

transmitting the field data to a routing node of the process using the different wireless communication protocol;

determining at the routing node an object device of the process for receiving the field data of the different wireless communication protocol;

sending the field data to the object device using the different wireless communication protocol; and

using the field data of the different wireless communication protocol sent to the object device to implement a function within the process.

2. The method of claim 1, wherein transmitting the field data using the first wireless communication protocol comprises transmitting the field data using a process control communication protocol associated with the at least one field device, and wherein converting the field data from the first wireless communication protocol to the different wireless communication protocol is performed by a conversion node of the process.

3. The method of claim 1, wherein the field node, the base node and the routing node form a mesh wireless communications network.

4. The method of claim 1, wherein the field node, the base node and the routing node form a point-to-point wireless communications network.

5. The method of claim 1, wherein the at least one field device is a HART protocol device.

6. The method of claim 1, wherein the at least one field device is a Fieldbus protocol device.

7. The method of claim 2, wherein the conversion node is integrated within the base node.

8. The method of claim 1, wherein the routing node sends the field data of the different wireless communication protocol through one or more repeaters to the object device.

9. The method of claim 2, wherein the process control communication protocol associated with the at least one field device is a combined analog and digital protocol.

10. The method of claim 2, wherein the process control communication protocol associated with the at least one field device is a bus-based digital protocol.

11. The method of claim 2, wherein the different wireless communication protocol is a low-power wireless networking protocol.

12. The method of claim 11, wherein the low-power wireless networking protocol is the EMBER communication protocol.

13. A method of using a wireless communication network in a process control system, the method comprising:

receiving process control data wirelessly at a first communication node of the wireless communication network using a first protocol;

converting the wirelessly received process control data from the first protocol to a different protocol at the first communication node;

determining a second communication node of the wireless communication network for receiving the process control data of the different protocol;

sending the process control data wirelessly to the second communication node using the different protocol; and

using the process control data sent wirelessly to the second communication node using the different protocol to implement a function within the process control system.

14. The method of claim 13, wherein receiving the process control data wirelessly at the first communication node using the first protocol includes receiving the process control data of the first protocol from a field device communicatively coupled to an additional communication node of the wireless communication network, wherein the field device performs a process control or measurement action within the process control system.

15. The method of claim 13, wherein receiving the process control data wirelessly at the first communication node using the first protocol includes wirelessly receiving data of the first protocol from a measuring device communicatively coupled to an additional communication node of the wireless communication network, wherein the measuring device measures one or more parameters which may affect the quality of the wireless communications within the wireless communication network, and wherein the data of the first protocol wirelessly received from the measuring device includes an indication of the one or more measured parameters.

16. The method of claim 13, wherein converting the wirelessly received process control data from the first protocol to the different protocol includes converting the wirelessly received process control data of the first protocol to a data packet of the different protocol, wherein the data packet of the different protocol includes:

the process control data of the different protocol; and

an indication of the second communication node.

17. The method of claim 13, wherein determining the second communication node for receiving the process control data of the different protocol is performed using a routing node of the wireless communication network, and wherein sending the process control data wirelessly to the second communication node using the different protocol includes sending the process control data wirelessly from the routing node to the second communication node using the different protocol.

18. The method of claim 13, wherein receiving the process control data wirelessly at the first communication node using the first protocol includes wirelessly receiving process control or measurement data from a field device within the process control system that communicates using the first protocol.

19. The method of claim 15, wherein receiving the process control data wirelessly at the first communication node using the first protocol further includes wirelessly receiving process control or measurement data of the first protocol from a field device within the process control system.

20. A method for controlling a process using a wireless communications network, the method comprising:

receiving field data from at least one field device;

transmitting the field data wirelessly from a field node to a base node using a first wireless communication protocol;

converting the field data from the first wireless communication protocol to a different wireless communication protocol;

transmitting the field data to a routing node using the different wireless communication protocol;

determining at the routing node an object device for receiving the field data of the different wireless communication protocol; and

sending the field data to the object device using the different wireless communication protocol,

wherein the first wireless communication protocol is the HART communication protocol, wherein the field data is transmitted wirelessly using the HART communication protocol, and wherein the field data is converted from the HART communication protocol to the different wireless communication protocol by a conversion node.