Continuous equipment operation in an automated control environment

• US 9,459,619 B2
• Filed: 06/29/2012
• Issued: 10/04/2016
• Est. Priority Date: 06/29/2011
• Status: Active Grant

• Current Assignee: Mega Fluid Systems, Inc. (Kinetics Holding GmbH)
• Original Assignee: Mega Fluid Systems, Inc. (Kinetics Holding GmbH)
• Inventors: Fletcher, Bryan Henry, Graves, James Andrew, Williams, Quay Isaac Gene, Allen, David Peter
• Primary Examiner(s): KASENGE, CHARLES R
• Application Number:
  US13/537,943
• Publication Number:
  US 20130006393A1
• Time in Patent Office: 1,558 Days
• Field of Search: 700/12, 700/21, 700/27, 700/79
• US Class Current: 1/1
• CPC Class Codes: G05B 23/0291 Switching into safety or degraded mode, e.g. protection and supervision after failure
• CPC Class Codes: G05B 9/02 electric

Abstract

Continuous equipment operation is facilitated despite disablement of an automation controller for controlling the equipment. A safe state in which equipment is to be maintained upon disablement of the automation controller is determined. Safe state data is provided for configuring an I/O module, through which the automation controller controls the equipment, with the safe state data to facilitate maintaining the equipment in the safe state during disablement of the automation controller. In one embodiment, upon subsequent enablement of the automation controller, a current state of the I/O module is evaluated and an automatic control state into which the equipment is to be transitioned is determined. The equipment is then transitioned to the determined automatic control state.

Claims

1. A method comprising:

determining a safe state in which equipment is to be maintained upon disablement of an automation controller, the automation controller configured to control the equipment by providing commands to an I/O module to control the equipment, the automation controller being a separate component from the I/O module; and

prior to a disablement of the automation controller in which control of the equipment by the automation controller is lost, performing;

configuring the I/O module with safe state data to facilitate maintaining, by the I/O module, the equipment in the safe state upon disablement of the automation controller in which control of the equipment by the automation controller is lost; and

configuring the I/O module to provide one or more signals, based on the safe state data, to the equipment upon disablement of the automation controller and loss of control of the equipment by the automation controller, wherein the configuring the I/O module with the safe state data and the configuring the I/O module to provide the one or more signals facilitates continuous equipment operation upon disablement of the automation controller despite the loss of control of the equipment by the automation controller during the disablement of the automation controller.

2. The method of claim 1, further comprising:

based on at least one of enablement or replacement of the automation controller, evaluating a current state of the I/O module, the current state reflecting a current state in which the equipment is being maintained;

determining, based on the evaluating, an automatic control state into which the equipment is to be transitioned; and

transitioning the equipment to the determined automatic control state.

3. The method of claim 1, wherein the disablement comprises a failure of the automation controller, and the loss of control of the equipment by the automation controller comprises a loss of communication between the I/O module and the automation controller.

4. The method of claim 1, wherein the equipment comprises the I/O module as a component thereof, and wherein the automation controller is a separate component from the equipment.

5. The method of claim 1, wherein the configuring the I/O module with safe state data is performed at least in part by a processor of the automation controller.

6. The method of claim 1, wherein the safe state data is built by a processor based on the determined safe state, and wherein the configuring the I/O module with the safe state data comprises providing the safe state data by the processor to the I/O module.

7. The method of claim 5, wherein the I/O module is a network I/O module, and wherein the processor is in communication with the network I/O module via one or more network connections.

8. The method of claim 1, wherein the configuring the I/O module with the safe state data occurs under normal operating conditions of the equipment, in which the automation controller is enabled.

9. The method of claim 1, wherein the equipment comprises industrial equipment, and wherein the automation controller comprises a programmable logic controller for controlling the industrial equipment.

10. The method of claim 1, further comprising:

receiving, by the I/O module, the safe state data and storing the safe state data in a safe state data store; and

based on disablement of the automation controller, transitioning, by the I/O module, operation of the equipment from a current state to the safe state.

11. A system comprising:

a memory; and

a processor in communication with the memory, wherein the system is configured to perform;

determining a safe state in which equipment is to be maintained upon disablement of an automation controller, the automation controller configured to control the equipment by providing commands to an I/O module to control the equipment, the automation controller being a separate component from the I/O module; and

prior to a disablement of the automation controller in which control of the equipment by the automation controller is lost, performing;

configuring the I/O module with safe state data to facilitate maintaining, by the I/O module, the equipment in the safe state upon disablement of the automation controller in which control of the equipment by the automation controller is lost; and

configuring the I/O module to provide one or more signals, based on the safe state data, to the equipment upon disablement of the automation controller and loss of control of the equipment by the automation controller, wherein the configuring the I/O module with the safe state data and the configuring the I/O module to provide the one or more signals facilitates continuous equipment operation upon disablement of the automation controller despite the loss of control of the equipment by the automation controller during the disablement of the automation controller.

12. The system of claim 11, wherein the processor is configured to execute program code stored in the memory to further perform:

based on at least one of enablement or replacement of the automation controller, evaluating a current state of the I/O module, the current state reflecting a current state in which the equipment is being maintained;

determining, based on the evaluating, an automatic control state into which the equipment is to be transitioned; and

transitioning the equipment to the determined automatic control state.

13. The system of claim 11, wherein the system comprises the automation controller and wherein the automation controller comprises the memory and the processor.

14. The system of claim 13, wherein the system further comprises the I/O module.

15. The system of claim 14, wherein the I/O module comprises another processor, the another processor configured to execute program code of the I/O module to perform:

receiving the safe state data and storing the safe state data in a safe state data store; and

based on disablement of the automation controller, providing the one or more signals to the equipment, wherein the one or more signals transition operation of the equipment from a current state to the safe state.

16. The system of claim 13, wherein the equipment comprises industrial equipment, and wherein the automation controller comprises a programmable logic controller for controlling the industrial equipment.

17. A computer program product comprising:

a non-transitory computer readable storage medium readable by a processor and storing instructions for execution by the processor to perform a method comprising;

determining a safe state in which equipment is to be maintained upon disablement of an automation controller, the automation controller configured to control the equipment by providing commands to an I/O module to control the equipment, the automation controller being a separate component from the I/O module; and

prior to a disablement of the automation controller in which control of the equipment by the automation controller is lost, performing;

configuring the I/O module with safe state data to facilitate maintaining, by the I/O module, the equipment in the safe state upon disablement of the automation controller in which control of the equipment by the automation controller is lost; and

configuring the I/O module to provide one or more signals, based on the safe state data, to the equipment upon disablement of the automation controller and loss of control of the equipment by the automation controller, wherein the configuring the I/O module with the safe state data and the configuring the I/O module to provide the one or more signals facilitates continuous equipment operation upon disablement of the automation controller despite the loss of control of the equipment by the automation controller during the disablement of the automation controller.

18. The computer program product of claim 17, wherein the method further comprises:

based on at least one of enablement or replacement of the automation controller, evaluating a current state of the I/O module, the current state reflecting a current state in which the equipment is being maintained;

determining, based on the evaluating, an automatic control state into which the equipment is to be transitioned; and

transitioning the equipment to the determined automatic control state.

19. The computer program product of claim 17, wherein the method further comprises building the safe state data by the processor based on the determined safe state, and wherein the configuring the I/O module with the safe state data comprises providing the safe state data by the processor to the I/O module.

20. The computer program product of claim 17, wherein the equipment comprises industrial equipment, and wherein the automation controller comprises a programmable logic controller for controlling the industrial equipment.

21. A method comprising:

receiving, by an I/O module, safe state data from an automation controller during a normal operating condition in which the automation controller controls equipment by providing commands to the I/O module to control the equipment, the I/O module and the automation controller being separate components, the I/O module configured with safe state data to facilitate maintaining, by the I/O module, the equipment in a safe state upon disablement of the automation controller in which control of the equipment by the automation controller is lost, and the I/O module configured to provide one or more signals, based on the safe state data, to the equipment upon disablement of the automation controller and loss of control of the equipment by the automation controller;

based on a disablement of the automation controller and loss of control of the equipment by the automation controller, recognizing, by the I/O module, the disablement of the automation controller, wherein the recognizing comprises the I/O module recognizing that control of the equipment by the automation controller is lost; and

based on the I/O module recognizing the disablement of the automation controller, automatically controlling, by the I/O module, the equipment based on the safe state data, in which the I/O module controls operation of the equipment during at least a portion of the disablement of the automation controller, despite the control of the equipment by the automation controller being lost.