Combined wired and wireless communications with field devices in a process control environment

• US 8,676,219 B2
• Filed: 04/10/2008
• Issued: 03/18/2014
• Est. Priority Date: 04/13/2007
• Status: Active Grant

• Current Assignee: FieldComm Group, Inc.
• Original Assignee: Hart Communication Foundation (FieldComm Group, Inc.)
• Inventors: Pratt, Wallace A. Jr., Nixon, Mark J., Rotvold, Eric D., Pramanik, Robin S., Lennvall, Tomas P.
• Primary Examiner(s): Eisner, Ronald
• Application Number:
  US12/100,986
• Publication Number:
  US 20080274766A1
• Time in Patent Office: 2,168 Days
• Field of Search: 4554221-4262, 455/448, 370/351, 370241-253, 370328-349, 370389-3951, 370/395.3, 3703955-39565, 370400-411, 370/475
• US Class Current: 455/448
• CPC Class Codes: G01D 21/00 Measuring or testing not otherwise provided for
• CPC Class Codes: H04W 24/00 Supervisory, monitoring or testing arrangements
• CPC Class Codes: H04W 56/0015 one node acting as a reference for the others
• CPC Class Codes: H04W 56/002 Mutual synchronization
• CPC Class Codes: H04W 80/00 Wireless network protocols or protocol adaptations to wireless operation

Abstract

A method of providing a wireless extension to a plant automation network connected to a plurality of wired devices, each wired device performing a process control function, includes connecting a plurality of wireless devices to the plant automation network, each of the plurality of wireless devices adapted to communicate with at least another one of the plurality of wireless devices via at least one respective wireless connection; and providing access to each of the plurality of wireless devices from a host disposed in the plant automation network, such that the host accesses the plurality of wired devices and the plurality of wireless devices using a common communication scheme.

Claims

1. A method of providing a wireless extension to a plant automation network connected to a plurality of wired devices, each wired device performing a process control function, the method comprising:

connecting a plurality of wireless devices to the plant automation network, each of the plurality of wireless devices adapted to communicate with at least another one of the plurality of wireless devices via at least one respective wireless connection;

providing a gateway device connected to at least one of the plurality of wireless devices via a wireless connection and to the automation network via a wired connection;

caching at least one of process data, alarm data, or device data as cache data related to one of the plurality of wireless devices at the gateway device, wherein caching the process data at the gateway device includes receiving, at the gateway device, an unsolicited burst mode data report from the one of the plurality of wireless devices; and

providing, to a host, access to each of the plurality of wireless devices, including receiving a change notification request from the host specifying a subset of the plurality of wired devices, and reporting the cached data to the host if the one of the plurality of wireless devices is associated with the subset,

wherein;

the host is disposed in the plant automation network,

the host executes at least one of an asset management application or an alarm diagnostic application of the plant automation network,

the host provides control and supervisory functions to personnel of a plant including the plant automation network,

the host is communicatively connected in a wired manner to the plurality of wired devices, and

the host accesses the plurality of wired devices and the plurality of wireless devices using a common communication scheme.

2. The method of claim 1, wherein the common communication scheme includes a network addressing scheme consistent with the Highway Addressable Remote Transducer (HART®

) protocol.

3. The method of claim 1,

wherein each of the plurality of wired devices communicates using a wired communication protocol;

wherein each of the plurality of wireless devices communicates using a wireless communication protocol; and

wherein providing, to the host, access to each of the plurality of wireless devices further includes;

receiving, from the host, a command compatible with the wired communication protocol;

determining whether the command is associated with one of the plurality of wired devices or one of the plurality of wireless devices; and

translating the command to the wireless communication protocol if the command is associated with one of the plurality of wireless devices.

4. The method of claim 1, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network including each of the plurality of wireless devices as a respective node and the gateway device as another node.

5. The method of claim 1, wherein providing a gateway device includes translating between a first protocol and a second protocol at the gateway device;

wherein the first protocol supports wired communications in the plant automation network and the wherein the second protocol supports wireless communications between the gateway device and each of the plurality of wireless devices.

6. The method of claim 1, further comprising, when a handheld device is physically proximate to one of the plurality of wireless devices:

providing, to the handheld device, wireless access to the one of the plurality of wireless devices by bypassing the gateway device, and directly and wirelessly connecting the handheld device to the one of the plurality of wireless devices.

7. The method of claim 6, wherein providing wireless access to the one of the plurality of wireless devices includes:

activating a scheduling resource reserved for the handheld device; and

allowing the handheld device to directly communicate with the one of the wireless devices and only within a time period associated with the scheduling resource reserved for the handheld device.

8. The method of claim 1, wherein caching the alarm data includes:

receiving, at the gateway device, an alarm from the one of the plurality of wireless devices;

generating an acknowledgement corresponding to the alarm;

generating a timestamp associated with a time of arrival of the alarm; and

caching the alarm in a memory of the gateway device for reporting to a requesting entity associated with the host.

10. The method of claim 1, wherein:

each of the plurality of wired devices communicates using a wired communication protocol having at least a first physical layer and an application layer layered over the first physical layer and zero or more intermediate layers;

each of the plurality of wireless devices communicates using a wireless communication protocol having at least a second physical layer and the application layer layered over the second physical layer and zero or more intermediate layers; and

the application layer is shared between the wired communication protocol and the wireless communication protocol.

11. The method of claim 10, wherein the application layer is consistent with the HART®

communication protocol.

12. The method of claim 1, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network wherein each of the plurality of wireless devices is a respective node of the mesh multi-node network;

the method further comprising;

operatively coupling at least one adapter device to one of the plurality of wired devices to enable the one of the plurality of wired devices to operate in the mesh multi-node network as another node of the mesh multi-node network.

13. The method of claim 1, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network including each of the plurality of wireless devices as a respective node;

the method further comprising;

accepting a request from a new wireless device not included in the plurality of wireless device to join the mesh multi-node network; and

allowing the host to access the new wireless device without restarting the mesh multi-node network.

9. A method of providing a wireless extension to a plant automation network connected to a plurality of wired devices, each wired device performing a process control function, the method comprising:

connecting a plurality of wireless devices to the plant automation network, each of the plurality of wireless devices adapted to communicate with at least another one of the plurality of wireless devices via at least one respective wireless connection;

providing a gateway device connected to at least one of the plurality of wireless devices via a wireless connection and to the automation network via a wired connection;

caching at least one of process data, alarm data, or device data as cache data related to one of the plurality of wireless devices at the gateway device; and

providing, to a host, access to each of the plurality of wireless devices, including receiving a change notification request from the host specifying a subset of the plurality of wired devices, and reporting the cached data to the host if the one of the plurality of wireless devices is associated with the subset,

wherein;

at least one of reporting the cached data and receiving the change notification request is associated with a real-time delivery mode and the other one of reporting the cached data and receiving the change notification request is associated with a non-real-time delivery mode,

the host is disposed in the plant automation network,

the host executes at least one of an asset management application or an alarm diagnostic application of the plant automation network,

the host provides control and supervisory functions to personnel of a plant including the plant automation network,

the host is communicatively connected in a wired manner to the plurality of wired devices, and

the host accesses the plurality of wired devices and the plurality of wireless devices using a common communication scheme.

14. The method of claim 9, wherein the common communication scheme includes a network addressing scheme consistent with the Highway Addressable Remote Transducer (HART®

) protocol.

15. The method of claim 9,

wherein each of the plurality of wired devices communicates using a wired communication protocol;

wherein each of the plurality of wireless devices communicates using a wireless communication protocol; and

wherein providing, to the host, access to each of the plurality of wireless devices further includes;

receiving, from the host, a command compatible with the wired communication protocol;

determining whether the command is associated with one of the plurality of wired devices or one of the plurality of wireless devices; and

translating the command to the wireless communication protocol if the command is associated with one of the plurality of wireless devices.

16. The method of claim 9, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network including each of the plurality of wireless devices as a respective node and the gateway device as another node.

17. The method of claim 9, wherein providing a gateway device includes translating between a first protocol and a second protocol at the gateway device;

wherein the first protocol supports wired communications in the plant automation network and the wherein the second protocol supports wireless communications between the gateway device and each of the plurality of wireless devices.

18. The method of claim 9, wherein caching the alarm data includes:

receiving, at the gateway device, an alarm from the one of the plurality of wireless devices;

generating an acknowledgement corresponding to the alarm;

generating a timestamp associated with a time of arrival of the alarm; and

caching the alarm in a memory of the gateway device for reporting to a requesting entity associated with the host.

19. The method of claim 9, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network wherein each of the plurality of wireless devices is a respective node of the mesh multi-node network;

the method further comprising;

operatively coupling at least one adapter device to one of the plurality of wired devices to enable the one of the plurality of wired devices to operate in the mesh multi-node network as another node of the mesh multi-node network.

20. The method of claim 9, wherein connecting a plurality of wireless devices to the plant automation network includes generating a mesh multi-node network including each of the plurality of wireless devices as a respective node;

the method further comprising;

accepting a request from a new wireless device not included in the plurality of wireless device to join the mesh multi-node network; and

allowing the host to access the new wireless device without restarting the mesh multi-node network.