Configuration based programmable logic controller (PLC) programming

• US 8,849,431 B2
• Filed: 03/01/2011
• Issued: 09/30/2014
• Est. Priority Date: 03/01/2011
• Status: Active Grant

• Current Assignee: Flow Data, Inc.
• Original Assignee: Flow Data, Inc.
• Inventors: Thomson, Keith, Brennan, Paul
• Primary Examiner(s): Shechtman, Sean
• Application Number:
  US13/038,368
• Publication Number:
  US 20120226368A1
• Time in Patent Office: 1,309 Days
• Field of Search: None
• US Class Current: 700/87
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/23297 Remote load of program with cellular, wireless, satellite connection

Abstract

Systems and methods for dynamic reconfiguration of an application of a programmable process controller are provided. According to one embodiment, a configuration device reads a new configuration file, which contains information regarding a desired number of instances and desired configurations of modules of the process control application, from its local memory. The configuration device then causes the application to instantiate the desired number of instances with the desired configurations by replacing an existing configuration file of the programmable process controller with the new configuration file. In another embodiment, a process control application of a programmable process controller dynamically configures its structure and memory allocation usage. During startup of the application, a configuration file is read that defines a number of instances and configurations of modules for the application. Based thereon, the application creates the defined number of instances of the modules having the defined configurations.

Claims

1. A method of reconfiguring a process control application stored in a memory of a programmable process controller for well automation, the method comprising:

providing a process control application in the programmable process controller having a collection of modules, each of which performs a predetermined set of tasks/operations with respect to well automation components, said process control application automatically configuring itself by creating a dynamic structure of the desired number and configuration of said modules in response to a configuration file;

reading, by a configuration device, a new configuration file from a memory of the configuration device, the new configuration file containing information regarding a desired number of instances and desired configurations of modules of the process control application for the programmable process controller reflecting the configuration of well automation components; and

causing, by the configuration device, the process control application in the programmable process controller to instantiate the desired number of instances of the modules with the desired configurations by replacing an existing external configuration file stored in the memory of the programmable process controller with the new configuration file.

2. The method of claim 1, wherein the programmable process controller comprises a Remote Terminal Unit (RTU).

3. The method of claim 1, wherein the programmable process controller comprises a Programmable Logic Controller (PLC).

4. The method of claim 3, wherein the PLC is selected from a group comprising a SCADAPack PLC, RTU or SCADASense Transmitter, Modicon Quantum PLC, a Modicon Premium PLC, a Modicon Momentum PLC, a Modicon M168 PLC, a Modicon M238, a Modicon M258 PLC, a Modicon LMCO58 motion controller and a Modicon TSX Micro PLC.

5. The method of claim 3, wherein the PLC includes an integrated short-range wireless radio.

6. The method of claim 5, wherein the integrated short-range wireless radio comprises a Bluetooth radio.

7. The method of claim 3, wherein the PLC includes a web server.

8. The method of claim 1, wherein the configuration device comprises a wireless mobile device.

9. The method of claim 8, wherein the wireless mobile device is selected from a group comprising a smart phone, a tablet computer and a laptop computer.

10. A process control architecture for well automation comprising:

a data bus;

at least two programmable process controllers residing on the data bus;

a process control application installed on each of the at least two programmable process controllers, said process control application having a collection of modules, each of which performs a predetermined set of tasks/operations with respect to well automation components, said process control application automatically configuring itself by creating a dynamic structure of the desired number and configuration of said modules in response to a configuration file; and

wherein, upon startup of the process control application, the at least two programmable process controllers each dynamically build different configurations of the process control application having differing numbers of instances of modules reflecting the configurations of well automation components for the at least two programmable process controllers as a result of the at least two programmable process controllers having different configuration files.

11. The process control architecture of claim 10, wherein the at least two programmable process controllers comprise a first Programmable Logic Controller (PLC) from a first family of PLCs sold by a PLC distributer and a second PLC from a second family of PLCs sold by the PLC distributer.

12. The process control architecture of claim 10, wherein the a main program of the process control application provides compatibility across a plurality of hardware platforms by a main program of the process control application instantiating a configuration object specialized for a hardware platform of the plurality of hardware platforms for which the process control application is compiled.

13. The process control architecture of claim 10, wherein the at least two programmable process controllers comprise a Programmable Logic Controller (PLC) and a Remote Terminal Unit (RTU).

14. A method comprising:

providing a process control application running on a programmable process controller for well automation, said process control application having a collection of modules, each of which performs a predetermined set of tasks / operations with respect to well automation components, said process control application automatically configuring itself by creating a dynamic structure of the desired number and configuration of said modules in response to a configuration file;

during startup of the process control application running on a programmable process controller for well automation, reading a configuration file associated with the process control application, the configuration file defining a number of instances and configurations of modules of the process control application for the programmable process controller reflecting the configuration of well automation components; and

instantiating, by the process control application, the defined number of instances of the modules with the defined configurations.

15. The method of claim 14, wherein the programmable process controller comprises a Programmable Logic Controller (PLC) or a Remote Terminal Unit (RTU).

16. The method of claim 15, further comprising:

receiving, by the programmable process controller, a new configuration file from a configuration device; and

during a second startup of the process control application, reading the new configuration file and responsive thereto instantiating, by the process control application, a number of instances of the modules different from the defined number and having configurations specified by the new configuration file.

17. The method of claim 14, wherein the configuration device comprises a wireless mobile device.

18. The method of claim 17, wherein the wireless mobile device is selected from a group comprising a smart phone, a tablet computer and a laptop computer.