Networked programmable industrial controllers

• US 9,823,640 B2
• Filed: 03/14/2013
• Issued: 11/21/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Power Control Technologies Incorporated
• Original Assignee: Power Control Technologies Incorporated
• Inventors: Crater, Kenneth C., Schermerhorn, Thomas N.
• Primary Examiner(s): Everett, Christopher E
• Application Number:
  US13/828,341
• Publication Number:
  US 20140277592A1
• Time in Patent Office: 1,713 Days
• CPC Class Codes: G05B 19/052 Linking several PLC's

Abstract

Different devices or subsystems, including programmable industrial controllers, are connected to a common network. Each connected device has the capability for autonomous or quasi-autonomous action based on a common pool of information accessible on the network. For example, all or a subset of devices connected to the network may periodically broadcast status data over the shared network medium; status data may include the current state of the controller and/or environmental conditions that the controller monitors.

Claims

1. A programmable industrial controller configured for communication with other programmable industrial controllers over a computer network, the controller comprising:

a network interface for communicating over the network;

a database for storing (i) a specification of at least one control function, (ii) controller state information, and (iii) state information, received over the network via the network interface, of other controllers;

a transmission module for periodically transmitting at least some of the controller state information over the network for broadcast to the other controllers;

an output interface for causing performance of the at least one control function; and

a memory partition for storing a control program comprising instructions for operating the network of controllers, the transmission module being configured to transmit segments of the control program to the network for execution by selected ones of the controllers based at least in part on the controller state information.

2. The controller of claim 1, wherein the state information comprises at least one of (i) a status of the controller, (ii) a status of a device operated by the controller, or (iii) an environmental condition sensed by the controller.

3. The controller of claim 1, further comprising logic circuitry for selecting a control function for performance via the output interface, the selection being based at least in part on the state of at least one other controller stored in the database.

4. The controller of claim 1, further comprising at least one sensor for sensing an external condition associated with a control function, wherein (i) the transmission module is configured to periodically transmit the sensed external condition over the network for broadcast to the other controllers and (ii) the database is configured to store external conditions sensed by other controllers and broadcast over the network.

5. The controller of claim 4, further comprising logic circuitry for selecting a control function for performance via the output interface, the selection being based at least in part on an external condition reported by at least one other controller stored in the database.

6. A system of linked programmable industrial controllers, the system comprising a plurality of programmable industrial controllers intercommunicating over a computer network, each of the controllers comprising a network interface for communicating over the network;

a database for storing (i) a specification of at least one control function, (ii) controller state information, and (iii) state information, received over the network via the network interface, of other controllers;

a transmission module for periodically transmitting at least some of the controller state information over the network for broadcast to the other controllers;

an output interface for causing performance of the at least one control function; and

a memory partition for storing a control program comprising instructions for operating the network of controllers, the transmission module being configured to transmit segments of the control program to the network for execution by selected ones of the controllers based at least in part on the controller state information.

7. The network of claim 6, further comprising at least one control node freely connectable to the network, the control node, when connected, receiving data from the controllers connected to the network, the control node comprising a display and a user interface for selectably displaying the data.

8. The network of claim 6, further comprising at least one history control node for receiving data from the controllers connected to the network and cumulatively storing the received data.

9. The network of claim 6, wherein the network interface is configured to receive commands directed toward one or more of the controllers and to broadcast the commands over the network.

10. The network of claim 6, wherein the databases of the controllers are configured to store data most recently transmitted from the other controllers, and further comprising a history node for storing cumulative data broadcast over the network.

11. The network of claim 6, wherein at least some of the controllers comprise logic circuitry for selecting a control function for performance via the output interface, the selection being based at least in part on the state of at least one other controller stored in the database.

12. A method of operating a linked network of programmable industrial controllers, the network comprising a plurality of programmable industrial controllers intercommunicating over the network, the method comprising the steps of:

periodically causing each of the controllers to broadcast status data over the network;

connecting a new controller to the network; and

continuously populating a database of the new controller with data received over the network from the other controllers, the populating step comprising (i) creating a database record for each of the controllers connected to the network, (ii) receiving state information from the other connected controllers, (iii) storing the state information from each of the controllers in an associated record of the database, and (iv) updating the database as new data is received from the other connected controllers,

wherein a designated one of the controllers stores a control program comprising instructions for operating the network of controllers, the designated controller transmitting segments of the control program to the network for execution by selected ones of the controllers based at least in part on the controller state information.

13. The method of claim 12, further comprising the steps of:

detecting departure of a controller from the network; and

deleting the database record corresponding to the departed controller.

14. The method of claim 12, further comprising the steps of:

detecting, by the intercommunicating controllers, entry of the new controller onto the network;

creating, at each of the intercommunicating controllers, a database entry for the new controller;

receiving, at each of the intercommunicating controllers, state information from the new controller; and

at each of the intercommunicating controllers, storing the state information from the new controller in the database entry created therefor.

15. The method of claim 12, wherein the network is an ad hoc network and the controllers communicate with each other directly over the network.