Distributed input/output control systems and methods

• US 8,942,831 B2
• Filed: 08/09/2010
• Issued: 01/27/2015
• Est. Priority Date: 10/05/2000
• Status: Expired due to Fees

• Current Assignee: EI Electronics LLC (Hubbell, Inc.)
• Original Assignee: EI Electronics LLC (Hubbell, Inc.)
• Inventors: Davlin, Karl A., Tannous, Adel George, Loudermilk, Alan R.
• Primary Examiner(s): Padmanabhan, Kavita
• Assistant Examiner(s): CHANG, SUNRAY
• Application Number:
  US12/852,895
• Publication Number:
  US 20110022186A1
• Time in Patent Office: 1,632 Days
• US Class Current: 700/3
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 2219/2231 Master slave
• CPC Class Codes: G05B 2219/24187 Redundant processors run identical programs

Abstract

Apparatus and methods for controlling a system that operates responsive to a plurality of input control signals are disclosed. During operation the system generates a plurality of output status/control signals. A master controller has at least first and second controllers. The first controller outputs and inputs signals over a first communication path, and the second controller outputs and inputs signals over a second communication path. The first and second controllers output signals based on input signals received over the first and second communication paths, respectively, and also based on stored control data. A plurality of input/output modules are provided. Each of the input/output modules has first and second slave controllers. The first slave controller of each of the input/output modules inputs and outputs signals over the first communication path to the first controller, and the second slave controller outputs and inputs signals over the second communication path. Each of the first slave controllers outputs and inputs signals to and from a first input/output circuit, and each of the second slave controllers outputs and inputs signals to and from a second input/output circuit. Each of the input/output modules also includes a combiner circuit. At least some of the input control signals for controlling the system are generated by the combiner circuit of each input/output module based on signals output from both the first and second input/output circuits. The output control signals for controlling the system are generated based on output status/control signals from the system that are coupled to each of the first and second input/output circuits of the input/output modules.

Claims

1. A distributed redundant control system utilizing inputs and outputs for controlling at least one piece of equipment, the system comprising:

a main controller module for controlling the at least one piece of equipment, the main controller module being configured to communicate a first signal to a plurality of input/output (I/O) modules over a first communication path and being configured to communicate a second signal to the plurality of I/O modules over a second communication path, wherein the first and second signals are redundant signals; and

each I/O module of the plurality of I/O modules comprising first and second slave controllers and first and second input/output (I/O) drivers, the first slave controller configured to input and output the first signal over the first communication path and input and output a first set of additional signals over a first additional communication path, the second slave controller configured to input and output the second signal over the second communication path and input and output a second set of additional signals over a second additional communication path, the first additional communication path being coupled to the first I/O driver and the second additional communication path being coupled to the second I/O driver;

wherein each of the first and second slave controllers of each of the plurality of I/O modules is configured to control a switch or relay of a corresponding I/O driver to turn an output of the corresponding I/O driver on or off.

2. The distributed redundant control system of claim 1, wherein the main controller module further comprises an interface for communicating to an external computer in accordance with a communication protocol.

3. The distributed redundant control system of claim 2, wherein the communication protocol comprises TCP/IP.

4. The distributed redundant control system of claim 2, wherein the communication protocol comprises USB.

5. The distributed redundant control system of claim 2, wherein the communication protocol comprises Firewire.

6. The distributed redundant control system of claim 2, wherein the communication protocol comprises RS232.

7. The distributed redundant control system of claim 1, wherein the main controller module comprises a plurality of interfaces for communication with an external computer in accordance with a plurality of communication protocols.

8. The distributed redundant control system of claim 7, wherein the communication protocols comprise two or more communication protocols selected from TCP/IP, USB, Firewire and RS232.

9. The distributed redundant control system of claim 1, wherein the input/output nodes are programmed to be either analog or digital inputs or outputs.

10. The distributed redundant control system of claim 1, wherein the first and second communication paths communicate to the plurality of I/O modules over a dual serial-type communication cable.

11. The distributed redundant control system of claim 1, wherein the main controller module communicates to the plurality of I/O modules over a single communication channel, wherein each of the plurality of I/O modules has an individual address.

12. The distributed redundant control system of claim 1, wherein the plurality of I/O modules are defined in the main controller module and the main controller module is adapted to poll the defined plurality of I/O modules to determine if each input/output is found.

13. The distributed redundant control system of claim 1, wherein the plurality of I/O modules are defined in the main controller module and the main controller module is adapted to poll the defined plurality of I/O modules to determine if each input/output has at least one error.

14. A distributed control system having redundant control, wherein an external system operates responsive to a plurality of control signals, wherein during operation the external system generates a plurality of output status/control signals, the distribution control system comprising:

a plurality of input/output modules, wherein each of the input/output modules comprises a first slave controller, a redundant, second slave controller, a first input/output circuit, and a second input/output circuit, wherein the first slave controller of each of the input/output modules inputs and outputs a first plurality of signals over a first communication path to a first controller of a master controller, wherein the redundant, second slave controller outputs and inputs a second plurality of signals over a second communication path to a second controller of the master controller, wherein the first plurality of signals and second plurality of signals are redundant signals, wherein each of the first slave controllers of each of the input/output modules outputs and inputs a first plurality of additional signals to and from the respective first input/output circuit, wherein each of the redundant, second slave controllers of each of the input/output modules outputs and inputs a second plurality of additional signals to and from the respective second input/output circuit, wherein each of the input/output modules is further configured for outputting control signals for controlling the external system, wherein the control signals are based on the first and second plurality of additional signals output from the first and second input/output circuits.

15. The distributed control system of claim 14, wherein the control signals for controlling the external system are based on the output status/control signals from the external system, the output status/control signals being provided to each of the first and second input/output circuits of the input/output modules.

16. The distributed control system of claim 14, wherein each of the input/output circuits comprises a predetermined number of input/output nodes, wherein the input/output nodes are programmed to be either inputs or outputs.

17. The distributed control system of claim 16, wherein the input/output nodes are programmed to be either analog or digital inputs or outputs.

18. The distributed control system of claim 14, wherein each input/output module is configured to perform a logic OR function to determine if the respective control signals should be generated.

19. The distributed control system of claim 14, wherein the additional signals from the input/output circuits are generated at least in part based on a majority vote logic operation to determine if the respective control signals should be generated.

20. The distributed control system of claim 14, wherein the first and second communication paths are coupled to the plurality of input/output modules at a plurality of different locations.

21. The distributed control system of claim 14, wherein the first and second slave controllers of each of the input/output modules are coupled together through an inter-controller communication path.

22. The distributed control system of claim 21, wherein the first and second slave controllers of each of the input/output modules perform redundancy checking based on signals exchanged over the inter-controller communication path.

23. A distributed control system having redundant control, wherein an external system operates responsive to a plurality of input control signals, wherein during operation the external system generates a plurality of output status/control signals, the distributed control system comprising:

a master controller having a first controller and a redundant, second controller, wherein the first controller outputs and inputs a first plurality of signals over a first communication path, wherein the redundant, second controller outputs and inputs the first plurality of signals over a second communication path, wherein the first and redundant, second controllers output a second plurality of signals based on input signals received over the first and second communication paths, respectively, and also based on stored control data, and

a plurality of input/output modules, wherein each of the input/output modules comprises a first slave controller, a redundant, second slave controller, a first input/output circuit, and a second input/output circuit;

wherein the first slave controller of each of the input/output modules outputs and inputs the second plurality of signals over the first communication path to and from the first controller, wherein the redundant, second slave controller outputs and inputs the second plurality of signals over the second communication path to and from the redundant, second controller, wherein each of the first slave controllers of the plurality of input/output modules outputs and inputs a third plurality of signals to and from the respective first input/output circuit, wherein each of the second slave controllers of the plurality of input/output modules outputs and inputs the third plurality of signals to and from the respective second input/output circuit, wherein each of the input/output modules further comprises a combiner circuit for outputting input control signals for controlling the external system, wherein the combiner circuit generates the input control signals based on redundant signals output from the respective first and second input/output circuits.

24. The distributed control system of claim 23, wherein the input control signals for controlling the external system are generated based on output status/control signals from the external system that are coupled to each of the first and second input/output circuits of the input/output modules.

25. The distributed control system of claim 23, wherein the master controller further comprises an interface for communicating to an external computer in accordance with a communication protocol.

26. The distributed control system of claim 25, wherein the communication protocol comprises TCP/IP.

27. The distributed control system of claim 25, wherein the communication protocol comprises USB.

28. The distributed control system of claim 25, wherein the communication protocol comprises Firewire.

29. The distributed control system of claim 25, wherein the communication protocol comprises RS232.

30. The distributed control system of claim 23, wherein the master controller comprises a plurality of interfaces for communication with an external computer in accordance with a plurality of communication protocols.

31. The distributed control system of claim 30, wherein the communication protocols comprise two or more communication protocols selected from TCP/IP, USB, Firewire and RS232.