Efficient architecture for interfacing redundant devices to a distributed control system

• US 8,516,296 B2
• Filed: 01/04/2011
• Issued: 08/20/2013
• Est. Priority Date: 04/16/2008
• Status: Active Grant

• Current Assignee: Schneider Electric Systems USA, Inc. (Schneider Electric SE)
• Original Assignee: Invensys Systems Incorporated (Invensys PLC)
• Inventors: Mendu, Krishna R.
• Primary Examiner(s): BONZO, BRYCE P
• Application Number:
  US12/983,958
• Publication Number:
  US 20110099416A1
• Time in Patent Office: 959 Days
• Field of Search: 714/4.1
• US Class Current: 714/4.1
• CPC Class Codes: G05B 9/03 with multiple-channel loop, i.e. redundant control systems
• CPC Class Codes: G06F 11/2005 using redundant communication controllers
• CPC Class Codes: G06F 11/2007 using redundant communication media

Abstract

A system and method for interfacing redundant devices to a distributed control system, includes a first and second redundant field bus modules communicably coupled to the distributed control system and to one another via switches. A pair of redundant field devices are coupled to the switches, one FD having an address. The FBMs adopt respective roles as master FBM and tracker FBM, so that the master FBM is configured to capture data from the one FD using the address, and to pass any data changes periodically to the tracker FBM, through the switches. The master FBM is configured to point to the other field device in the event the other field device has assumed the address. The FBMs are configured to switch roles in the event communication is disrupted between the master FBM and the FD having the address.

Claims

1. A system for interfacing redundant devices to a distributed control system, the system comprising:

a first field bus module (FBM) communicably coupled to the distributed control system;

the first FBM coupled to a first switch;

a second FBM communicably coupled to the distributed control system;

the second FBM coupled to a second switch;

the first and second FBMs communicably coupled to one another by the switches;

a pair of field devices (FDs), coupled to the switches;

the FDs being redundant of one another, wherein data is synchronized therebetween;

one FD of the pair having an address;

the first and second FBMs being redundant of one another, wherein data is synchronized therebetween through the first and second switches;

the first and second FBMs configured to adopt respective roles as master FBM and tracker FBM, wherein the master FBM is configured to capture data from the one FD using the address, and to pass any data changes periodically to the tracker FBM, through the switches;

the other FD of the pair configured to assume the address in the event of a failure of the one FD;

the master FBM configured to point to the other field device in the event the other field device has assumed the address;

the first and second FBMs configured to switch roles in the event communication is disrupted between the master FBM and the FD having the address;

wherein the system is redundant so that data is preserved in the event of failure of any one of the FBMs, FDs or switches.

2. The system of claim 1, wherein the redundant FDs comprise programmable logic controllers (PLCs).

3. The system of claim 2, wherein the other FD is configured to, upon assumption of the address, broadcast its ownership of the address to the FBMs, so that either of the FBMs can point to, and capture data therefrom.

4. The system of claim 3, wherein the tracker FBM is synchronized with the master FBM independently of any communication with the FDs.

5. The system of claim 4, wherein the tracker FBM and master FBM are synchronized independently of any off-network (out of band) communication therebetween.

6. The system of claim 5, wherein the tracker FBM and master FBM are synchronized using only a single data stream from the FDs to the FBMs.

7. The system of claim 6, wherein the tracker FBM is synchronized by sending only changes in data from the master FBM.

8. The system of claim 1, wherein the master FBM is configured to point to the other field device in real time, in the event the other field device has assumed the address.

9. The system of claim 1, wherein the master FBM is configured to use a single port for communication with the FD, and for communication with the tracker FBM.

10. The system of claim 1, comprising a field control processor (FCP) coupled to the first and second FBMs.

11. The system of claim 1, comprising a local communications link disposed between the first and second FDs for synchronizing the FDs.

24. The system of claim 1, wherein at least one of the first and second switches comprises an Ethernet switch.

25. The system of claim 1, wherein the address comprises a floating IP address.

12. A method of interfacing redundant devices to a distributed control system, the system comprising:

(a) communicably coupling a first field bus module (FBM) to the distributed control system;

(b) coupling the first FBM to a first switch;

(c) communicably coupling a second FBM to the distributed control system;

(d) coupling the second FBM to a second switch;

(e) communicably coupling the first and second FBMs to one another by the switches;

(f) coupling a pair of field devices (FDs) to the switches, the FDs being redundant of one another, wherein data is synchronized therebetween, one FD of the pair having an address;

(g) configuring the first and second FBMs to be redundant of one another, wherein data is synchronized therebetween through the first and second switches;

(h) configuring the first and second FBMs to adopt respective roles as master FBM and tracker FBM, wherein the master FBM is configured to capture data from the one FD using the address, and to pass any data changes periodically to the tracker FBM, through the switches;

(i) configuring the other FD of the pair to assume the address in the event of a failure of the one FD;

(j) configuring the master FBM to point to the other field device in the event the other field device has assumed the address; and

(k) configuring the first and second FBMs to switch roles in the event communication is disrupted between the master FBM and the FD having the address;

wherein the system is redundant so that data is preserved in the event of failure of any one of the FBMs, FDs or switches.

13. The method of claim 12, wherein the redundant FDs comprise programmable logic controllers (PLCs).

14. The system of claim 13, comprising configuring the FBMs to receive a notification that the other FD has assumed the address, so that either of the FBMs can point to, and capture data therefrom.

15. The method of claim 14, comprising synchronizing the tracker FBM with the master FBM independently of any communication with the FDs.

16. The method of claim 15, comprising synchronizing the tracker FBM and master FBM independently of any off-network (out of band) communication therebetween.

17. The method of claim 16, comprising synchronizing the tracker FBM and master FBM using only a single data stream from the FDs to the FBMs.

18. The method of claim 17, comprising synchronizing the tracker FBM by sending only changes in data from the master FBM.

19. The method of claim 12, comprising configuring, in real time, the master FBM to point to the other field device, in the event the other field device has assumed the address.

20. The method of claim 12, comprising configuring the master FBM to use a single port for communication with the FD, and for communication with the tracker FBM.

21. The method of claim 12, comprising coupling a field control processor (FCP) to the first and second FBMs.

22. The method of claim 12, comprising disposing a local communications link between the first and second FDs for FD synchronization.

26. The method of claim 12, using at least one of the first and second switches in the form of an Ethernet switch.

27. The method of claim 12, using an address in the form of a floating IP address.

23. An article of manufacture for interfacing redundant devices to a distributed control system, said article of manufacture comprising:

a computer usable medium having a computer readable program code embodied therein, said computer usable medium having;

computer readable program code for;

(a) communicably coupling a first field bus module (FBM) to the distributed control system;

(b) coupling the first FBM to a first switch;

(c) communicably coupling a second FBM to the distributed control system;

(d) coupling the second FBM to a second switch;

(e) communicably coupling the first and second FBMs to one another by the switches;

(f) coupling a pair of field devices (FDs) to the switches, the FDs being redundant of one another, wherein data is synchronized therebetween, one FD of the pair having an address;

(g) configuring the first and second FBMs to be redundant of one another, wherein data is synchronized therebetween through the first and second switches;

(h) configuring the first and second FBMs to adopt respective roles as master FBM and tracker FBM, wherein the master FBM is configured to capture data from the one FD using the address, and to pass any data changes periodically to the tracker FBM, through the switches;

(i) configuring the other FD of the pair to assume the address in the event of a failure of the one FD;

(j) configuring the master FBM to point to the other field device in the event the other field device has assumed the address; and

(k) configuring the first and second FBMs to switch roles in the event communication is disrupted between the master FBM and the FD having the address;

wherein the system is redundant so that data is preserved in the event of failure of any one of the FBMs, FDs or switches.