Flexible input/output devices for use in process control systems

• US 8,761,196 B2
• Filed: 09/29/2006
• Issued: 06/24/2014
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Law, Gary Keith, Schleiss, Trevor Duncan, Burr, Kent, Snead, Thomas W., Eddie, Ronald Dean
• Primary Examiner(s): NGUYEN, STEVEN H D
• Application Number:
  US11/540,063
• Publication Number:
  US 20080080395A1
• Time in Patent Office: 2,825 Days
• Field of Search: None
• US Class Current: 370/464
• CPC Class Codes: G05B 19/4186 by protocol, e.g. MAP, TOP
• CPC Class Codes: G05B 2219/31181 Controller and device have several formats and protocols, select common one
• CPC Class Codes: H04L 41/0803 Configuration setting
• 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

Methods, apparatus and articles of manufacture are disclosed that provide flexible input/output device communications in a process control system. In one example, a process control system controls a plurality of field devices. The process control system includes a control device and a communications protocol component. The communications protocol component has at least one communications channel that is selectively configurable to use at least a first or second communications protocol and to communicate with at least one of the field devices.

Claims

1. A process control system to control a plurality of field devices, the process control system comprising:

a control device; and

an input/output card, the input/output card having a communication protocol component, the communication protocol component comprising;

a first communications channel that is selectively configurable to use one of a plurality of communication protocols and to communicate with at least one of the field devices, and

a second communications channel that is selectively configurable to use one of a plurality communication protocols and to communicate with at least one of the field devices,

wherein the first channel, when configured to use a first communication protocol, communicates with a first one of the field devices while the second channel, when configured to use a second communication protocol, is enabled to simultaneously communicate with a second one of the field devices,

wherein the second communication protocol is different than the first communication protocol,

wherein each of the plurality of communications channels is coupled to a respective reconfigurable component of the communication protocol component and the reconfigurable components are configurable using a configuration application associated with the process control system, and

wherein the configuration application is enabled to selectively and independently configure the reconfigurable components.

2. A process control system as defined in claim 1, wherein the first or the second communication protocol is selectable for each of a plurality of communications channels associated with the field devices.

3. A process control system as defined in claim 1, wherein the control device is configured to assign addresses to the field devices.

4. A process control system as defined in claim 1 further comprising a handheld configuration tool, wherein the handheld configuration tool is configured to assign addresses to the field devices.

5. A process control system as defined in claim 1, wherein the configuration application is created using one tool.

6. A process control system as defined in claim 5, wherein the one tool is an application configured to he executed via a workstation.

7. A process control system as defined in claim 1, wherein the configuration application is incorporated within an object-oriented database.

8. A process control system as defined in claim 1, wherein the configuration application is self-documenting.

9. A process control system as defined in claim 1, wherein the configuration application provides information related to the sensing of the field devices by the input/output card.

10. A process control system as defined in claim 1, wherein the configuration application is configured to clear address assignments of the field devices.

11. A process control system as defined in claim 1, wherein the configuration application is configured to use a device definition to describe an input, an output, or a parameter associated with a particular one of the field devices.

12. A process control system as defined in claim 11, wherein the device definition is imported into a configuration database in a bulk format or through a user creation.

13. A process control system as defined in claim 11, wherein the device definition is generated using a product description.

14. A process control system as defined in claim 11, wherein the device definition is created as the particular one of the field devices is added to the process control system.

15. A process control system as defined in claim 11, wherein cues for creating the device definition are provided to a user based on a communication protocol used to communicate with the particular one of the field devices.

16. A process control system as defined in claim 11, wherein the configuration application is configured to generate signal tags with labels related to the device definition.

17. A process control system as defined in claim 1, wherein the configuration application is configured to generate device alerts on a per field device basis for any one of a plurality of communication protocols used to communicate with the field devices.

18. A process control system as defined in claim 1, wherein the process control system is configured to use the input/output card and a redundant input/output card.

19. A process control system as defined in claim 1, wherein the configuration application supports pass-through communications from a workstation-based device configuration application.

20. A process control system as defined in claim 1 further comprising a redundant input/output card, the redundant input/output card having a second communication protocol component, the second communication protocol component comprising:

a third communications channel that is selectively configurable to use one of a plurality of communication protocols and to communicate with at least one of the field devices, and

a fourth communications channel that is selectively configurable to use one of a plurality communication protocols and to communicate with at least one of the field devices, and

wherein the third channel, when configured to use the first communication protocol, communicates with the first one of the field devices or a third one of the field devices, while the fourth channel, when configured to use the second communication protocol, is enabled to simultaneously communicate with the second one of the field devices or a fourth one of the field devices,

wherein each of the plurality of communications channels is coupled to a respective reconfigurable component of the second communication protocol component and the reconfigurable components are configurable using a configuration application associated with the process control system, and

wherein the configuration application is enabled to selectively and independently configure the reconfigurable components.

21. A process control system as defined in claim 1, wherein the communications protocol component further comprises:

a third communications channel that is selectively configurable to use one of a plurality of communication protocols and to communicate with at least one of the field devices,

wherein the third channel, when configured to use a third communication protocol, communicates with a third one of the field devices while the first channel, when configured to use the first communication protocol, is enabled to simultaneously communicate with the first one of the field devices, and the second channel, when configured to use the second communication protocol, is enabled to simultaneously communicate with the second one of the field devices,

wherein the third communication protocol is different than the first communication protocol and the second communication protocol, and

wherein the third channel is coupled to a respective reconfigurable component of the communications protocol component that is selectively and independently configurable using a configuration application associated with the process control system.

22. A process control system as defined in claim 21 further comprising a redundant input/output card, the redundant input/output card having a second communication protocol component, the second communication protocol component comprising:

a fourth communications channel that is selectively configurable to use one of a plurality of communication protocols and to communicate with at least one of the field devices,

a fifth communications channel that is selectively configurable to use one of a plurality communication protocols and to communicate with at least one of the field devices, and

a sixth communications channel that is selectively configurable to use one of a plurality communication protocols and to communicate with at least one of the field devices,

wherein the fourth channel, when configured to use the first communication protocol, communicates with the first one of the field devices or a fourth one of the field devices, while the fifth channel, when configured to use the second communication protocol, is enabled to simultaneously communicate with the second one of the field devices or a fifth one of the field devices, while the sixth channel, when configured to use the third communication protocol, is enabled to simultaneously communicate with the third one of the field devices or a sixth one of the field devices,

wherein each of the plurality of communications channels is coupled to a respective reconfigurable component of the second communication protocol component and the reconfigurable components are configurable using a configuration application associated with the process control system, and

wherein the configuration application is enabled to selectively and independently configure the reconfigurable components.

23. An input/output card for use in a process control system, the input/output card comprising:

a communication protocol component comprising;

a first communications channel to establish communications between at least one of a plurality of field devices and a control device using a first of one of a plurality of available communication protocols, and

a second communications channel to simultaneously establish communications between at least another of the plurality of field devices and the control device using a second one of the plurality of available communication protocols,

wherein the second communication protocol is different than the first communication protocol,

wherein each of the plurality of communications channels is coupled to a respective reconfigurable component of the communication protocol component and the reconfigurable components are configurable using a configuration application associated with the process control system, and

wherein the configuration application is enabled to selectively and independently configure the reconfigurable components.

24. An input/output card as defined in claim 23, wherein the first or second communication protocol is selectable for each of the plurality of field devices.

25. An input/output card as defined in claim 23, wherein the input/output card is configurable remotely.

26. An input/output card as defined in claim 23, wherein the input/output card is configured to automatically sense the field devices.

27. A method of controlling a plurality of field devices, the method comprising:

initializing an input/output card that includes a communication protocol component having a plurality of reconfigurable components that are respectively coupled to a plurality of communications channels;

configuring the reconfigurable components of the communication protocol component by extending a configuration application associated with a control system, wherein the configuration application is enabled to selectively and independently configure the reconfigurable components;

configuring a first communications channel of the plurality of communications channels to use a first of a plurality of available communication protocols; and

configuring a second communications channel of the plurality of communications channels to use a second of the plurality of available communication protocols, wherein the second communication protocol is different than the first communication protocol;

communicating with one of the field devices via the first communications channel using the first communication protocol; and

simultaneously communicating with another of the field devices via the second communications channel using the second communication protocol.

28. A method as defined in claim 27 further comprising selectively configuring the input/output card to use the first communication protocol or the second communication protocol for each of the plurality of field devices.

29. A method as defined in claim 27 further comprising using a control device to assign addresses to the field devices.

30. A method as defined in claim 27 further comprising using a handheld configuration tool to assign addresses to the field devices when a control system is offline.

31. A method as defined in claim 27 further comprising creating the configuration application using a single tool.

32. A method as defined in claim 31, wherein the single tool is an application running on a workstation.

33. A method as defined in claim 27 further comprising incorporating the configuration application into a single object-oriented database.

34. A method as defined in claim 27, wherein the configuration application is self-documenting.

35. A method as defined in claim 27 further comprising using the configuration application to provide information related to the sensing of the field devices by an interface card.

36. A method as defined in claim 27 further comprising using the configuration application to clear address assignments of the field devices.

37. A method as defined in claim 27, wherein the configuration application uses a device definition to describe an input, an output, or a parameter of a particular one of the field devices.

38. A method as defined in claim 37 further comprising importing the device definition into a configuration database in a bulk format or via an interaction with a user.

39. A method as defined in claim 38, wherein the user creates the device definition from a product description.

40. A method as defined in claim 37, wherein the user creates the device definition as the particular one of the field devices is added to the control system.

41. A method as defined in claim 37 further comprising providing cues for creating the device definition to the user based on the communication protocol used to communicate with the particular one of the field devices.

42. A method as defined in claim 37 further comprising using the configuration application to generate signal tags with labels related to the device definition.

43. A method as defined in claim 27 further comprising using the configuration application to generate device alerts on a per field device basis for any one of a plurality of communication protocols.

44. A method as defined in claim 27 further comprising supporting redundant interface cards.

45. A method as defined in claim 27 further comprising supporting pass-through communications from a workstation-based device configuration application.

46. A machine accessible storage device or storage disc comprising instructions that, when executed, cause a machine to control at least one of a plurality of field devices by:

initializing an input/output card that includes a communication protocol component having a plurality of reconfigurable components that are respectively coupled to a plurality of communications channels;

configuring the communication protocol component by extending a configuration application associated with a control system, wherein the configuration application is enabled to selectively and independently configure the reconfigurable components;

configuring a first communications channel of the plurality of communications channels to use a first of a plurality of available communication protocols; and

configuring a second communications channel of the plurality of communications channels to use a second of the plurality of available communication protocols, wherein the second communication protocol is different than the first communication protocol;

communicating with one of the field devices via the first communications channel using the first communication protocol; and

simultaneously communicating with another of the field devices via the second communications channel using the second communication protocol.

47. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to select the first communication protocol or the second communication protocol for each of the plurality of field devices.

48. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to use a control device to assign addresses to the field devices.

49. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to communicate with a handheld configuration tool to assign addresses to the field devices when a control system is offline.

50. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to create the configuration application using a single tool.

51. A machine accessible storage device or storage disc as defined in claim 50, wherein the single tool is an application running on a workstation.

52. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to incorporate the configuration application into a single object-oriented database.

53. A machine accessible storage device or storage disc as defined in claim 46, wherein the configuration application is self-documenting.

54. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to use the configuration application to provide information related to the sensing of the field devices by an interface card.

55. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to use the configuration application to clear address assignments of the field devices.

56. A machine accessible storage device or storage disc as defined in claim 46, wherein the configuration application uses a device definition that describes an input, an output, or a parameter associated with a particular one of the field devices.

57. A machine accessible storage device or storage disc as defined in claim 56, wherein the instructions, when executed cause the machine to import the device definition into a configuration database in a bulk format via interaction with a user.

58. A machine accessible storage device or storage disc as defined in claim 57, wherein the device definition is user generated from a product description.

59. A machine accessible storage device or storage disc as defined in claim 56, wherein the user creates the device definition as the one of the particular field devices is added to the process control system.

60. A machine accessible storage device or storage disc as defined in claim 56, wherein the instructions, when executed cause the machine to provide cues for creating the device definition to the user based on the communication protocol used to communicate with the particular one of the field devices.

61. A machine accessible storage device or storage disc as defined in claim 56, wherein the instructions, when executed cause the machine to use the configuration application to generate signal tags with labels related to the device definition.

62. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to use the configuration application to generate device alerts on a per field device basis for any one of a plurality of communication protocols.

63. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to support redundant interface cards.

64. A machine accessible storage device or storage disc as defined in claim 46, wherein the instructions, when executed cause the machine to support pass-through communications from a workstation-based device configuration application.

65. A method of using an input/output card including a communication protocol component having a plurality of reconfigurable components respectively coupled to a plurality of communications channels in a process control system to communicate using a plurality of communication protocols, the method comprising:

configuring the communication protocol component by extending a configuration application associated with a control system, wherein the configuration application is enabled to selectively and independently configure the reconfigurable components of the input/output card;

configuring at least first one of a plurality of communications channels of the input-output card to communicate with at least one of a plurality of field devices using a first communication protocol; and

configuring at least a second one of the plurality of communications channels of the input-output card to communicate with at least another one of the plurality of field devices using a second communication protocol, wherein the first and second communications channels are to use the first and second communication protocols, respectively, simultaneously, wherein the second communication protocol is different than the first communication protocol.

66. A method as defined in claim 65 further comprising selecting the first communication protocol or the second communication protocol for any of the plurality of field devices on a per connection basis.

67. A method as defined in claim 65 further comprising configuring the input/output card remotely.

68. A method as defined in claim 65, wherein the input/output card is configured to automatically sense the field devices.