Apparatus and methods to communicatively couple field devices to controllers in a process control system

• US 9,083,548 B2
• Filed: 09/23/2008
• Issued: 07/14/2015
• Est. Priority Date: 09/23/2008
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Holmes, David, Law, Gary Keith
• Primary Examiner(s): Nam, Hyun
• Application Number:
  US12/236,165
• Publication Number:
  US 20100077111A1
• Time in Patent Office: 2,485 Days
• Field of Search: 710/11
• US Class Current: 1/1
• CPC Class Codes: G05B 2219/25014 Fieldbus general name of bus connected to machines, detectors, actuators
• CPC Class Codes: G05B 2219/25248 Microcontroller as time switch
• CPC Class Codes: H04L 12/40013 Details regarding a bus controller
• CPC Class Codes: H04L 2012/40221 Profibus
• CPC Class Codes: H04L 2012/40254 Actuator Sensor Interface ASI
• CPC Class Codes: H04L 43/50 Testing arrangements
• CPC Class Codes: H04L 67/12 specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
• CPC Class Codes: H04L 69/18 Multiprotocol handlers, e.g. single devices capable of handling multiple protocols

Abstract

Example apparatus and methods to communicatively couple field devices to controllers in a process control system are disclosed. An example method of changing a communication protocol of a first field device in a process control system includes decoupling from the first field device a first removable communication module configured to communicate using a first communication protocol. The example method also includes coupling to the first field device a second removable communication module configured to communicate using a second communication protocol. After coupling the second removable communication module, the first field device is configured to communicate using the second communication protocol. In addition, the first field device is coupled to a first communication channel on an input/output card when communicating using the first communication protocol and the first field device is coupled to the first communication channel on the input/output card when communicating using the second communication protocol.

Claims

1. A method of changing a communication protocol of a first field device in a process control system, the method comprising:

decoupling from the first field device a first removable communication module configured to communicate using a first communication protocol, wherein the first communication module is removably coupled via a connector configured to enable removable coupling of the first communication module and the first field device; and

coupling to the first field device a second removable communication module configured to communicate using a second communication protocol, wherein after coupling the second removable communication module, the first field device is configured to communicate using the second communication protocol, and wherein the first field device is coupled to a first communication channel on an input/output card when communicating using the first communication protocol and the first field device is coupled to the first communication channel on the input/output card when communicating using the second communication protocol.

2. A method as defined in claim 1, further comprising:

decoupling from the first communication channel of the input/output card, a third removable communication module configured to communicate using the first communication protocol; and

coupling to the input/output card a fourth removable communication module configured to communicate using the second communication protocol, wherein the fourth removable communication module is coupled to the first communication channel.

3. A method as defined in claim 1, wherein each of the first removable communication module and the second removable communication module provides substantially all communication software and electronics to the first field device.

4. A method as defined in claim 3, wherein the communications software includes revision software.

5. A method as defined in claim 4, wherein the revision software includes new features.

6. A method as defined in claim 3, wherein the communications software includes industry standards information.

7. A method as defined in claim 1, wherein the first removable communication module, when removed from the first field device, is couplable to a second field device.

8. A method as defined in claim 7, wherein the first field device is a different than the second field device.

9. A method as defined in claim 8, wherein the first field device is a different make or model than the second field device.

10. A method as defined in claim 1, wherein at least one of the first removable communication module or the second removable communication module includes isolation circuitry to electronically isolate the first field device.

11. A method as defined in claim 1, wherein the second removable communication module includes at least one of diagnostic software or electronics for use with the first field device.

12. A method as defined in claim 1, wherein at least one of the first removable communication module or the second removable communication module includes one or more contacts to mechanically and communicatively couple the first removable communication module or the second removable communication module to the first field device.

13. A method as defined in claim 12, wherein at least one of the first removable communication module or the second removable communication module is pluggable into the first field device.

14. A method as defined in claim 1, wherein at least one of the first removable communication module or the second removable communication module is coupled to the first field device via a base.

15. A method as defined in claim 1, wherein at least one of the first removable communication module or the second removable communication module includes local tagging information.

16. A method as defined in claim 15, wherein the local tagging information includes a serial number.

17. A method as defined in claim 1, wherein at least one of the first removable communication module or the second removable communication module contains information to configure or evaluate the field device.

18. A distributed process control system comprising:

an input/output card having a plurality of communication channels; and

a first field device having a first communication module removably coupled thereto to communicate using a first communication protocol, wherein the first communication module is removably coupled via a connector configured to enable removable coupling of the first communication module and the first field device, wherein the first field device is coupled to a first of the plurality of communication channels, wherein a second communication module is removably couplable to the first field device to replace the first communication module to communicate using a second communication protocol while the first field device is coupled to the first of the plurality of communication channels.

19. A system as defined in claim 18, further comprising a third removable communication module communicatively coupled to the first removable communication module to communicate therewith using the first communication protocol, wherein a fourth communication module is removably couplable to the second communication module to replace the third communication module to communicate using the second communication protocol.

20. A system as defined in claim 18, wherein the first and second communication protocols are different.

21. A system as defined in claim 18, wherein when removed from the first field device, the first communication module is coupled to a second field device.

22. A system as defined in claim 21, wherein the first field device is different than the second field device.

23. A system as defined in claim 22, wherein the first field device is a different make or model than the second field device.

24. A system as defined in claim 18, wherein the first communication module provides substantially all communications software and communications electronics to the first field device.

25. A system as defined in claim 24, wherein the communications software includes revision software.

26. A system as defined in claim 25, wherein the revision software includes new features.

27. A system as defined in claim 24, wherein the communications software includes industry standards information.

28. A system as defined in claim 18, wherein at least one of the first communication module or the second communication module includes isolation circuitry to electronically isolate the first field device.

29. A system as defined in claim 18, wherein the second communication module includes at least one of diagnostic software or electronics for the first field device.

30. A system as defined in claim 18, wherein at least one of the first communication module or the second communication module includes one or more contacts to mechanically and communicatively couple the first communication module or the second communication module to the first field device.

31. A system as defined in claim 18, wherein at least one of the first communication module or the second communication module is pluggable into the first field device.

32. A system as defined in claim 18, wherein at least one of the first communication module or the second communication module is coupled to the first field device via a base.

33. A system as defined in claim 18, wherein at least one of the first removable communication module or the second removable communication module includes local tagging information.

34. A system as defined in claim 33, wherein the local tagging information includes a serial number.

35. A system as defined in claim 18, wherein at least one of the first removable communication module or the second removable communication module contains information to configure or evaluate the field device.