Wireless architecture and support for process control systems

• US 9,992,726 B2
• Filed: 02/15/2016
• Issued: 06/05/2018
• Est. Priority Date: 06/18/2003
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Shepard, John R., Nelson, Joe
• Primary Examiner(s): Patel, Jay P
• Application Number:
  US15/043,941
• Publication Number:
  US 20160165516A1
• Time in Patent Office: 841 Days
• CPC Class Codes: G05B 2219/21079 Allocate at start up also to each controlled device a code for the master
• CPC Class Codes: G05B 2219/25061 Configuration stored in central database
• CPC Class Codes: G05B 2219/25101 Detect connected module, load corresponding parameters, variables into module
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31123 Multi mode network controller, monitor, control, configuration, maintenance
• CPC Class Codes: G05B 2219/31151 Lan local area network
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: H04W 40/24 Connectivity information management, e.g. connectivity discovery or connectivity update
• CPC Class Codes: H04W 76/14 Direct-mode setup
• CPC Class Codes: H04W 8/20 Transfer of user or subscriber data
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A wireless communication system for use in a process environment uses mesh and possibly a combination of mesh and point-to-point communications to produce a wireless communication network that can be easily set up, configured, changed and monitored, thereby making a wireless communication network that is less expensive, and more robust and reliable. The wireless communication system allows virtual communication paths to be established and used within the process control system in a manner that is independent of the manner in which the wireless signals are sent between different wireless transmitting and receiving devices within the process plant. Still further, communication analysis tools are provided to enable a user or operator to view the operation of the wireless communication network to thereby analyze the ongoing operation of the wireless communications within the wireless communication network.

Claims

1. A wireless communication network disposed in a process control system, the wireless communication network comprising:

a plurality of communication nodes each including a wireless transceiver, the one or more wireless transceivers of the one or more communication nodes implementing wireless communications within the wireless communication network, wherein the plurality of communication nodes include a first communication node and a second communication node;

one or more field devices each performing a process control action within the process plant, each of the one or more field devices being communicatively coupled to at least one of the plurality of communication nodes; and

a host device configured to;

collect, from at least one of the plurality of communication nodes, data related to the operation of the wireless communications within the wireless communication network; and

process the collected data to determine one or more wireless communication network performance factors indicative of the quality of the wireless communications within the wireless communication network, wherein one of the one or more wireless communication network performance factors includes an indication of a wireless communication capability between the first communication node and the second communication node.

2. The wireless communication network of claim 1, wherein the wireless communication capability indicated by the one wireless communication network performance factor is direct two-way wireless communication between the first communication node and the second communication node.

3. The wireless communication network of claim 1, wherein the wireless communication capability indicated by the one wireless communication network performance factor is direct one-way wireless communication from the first communication node to the second communication node.

4. The wireless communication network of claim 1, wherein the wireless communication capability indicated by the one wireless communication network performance factor is indirect wireless communication between the first communication node and the second communication node using at least one additional communication node of the wireless communication network.

5. The wireless communication network of claim 1, wherein the host device includes an operator interface, and wherein the operator interface allows an operator to change one or more operational parameters of the wireless communication network in order to affect the one or more wireless communication network performance factors.

6. The wireless communication network of claim 5, wherein the one or more operational parameters include a signal strength of a signal wirelessly communicated between the first communication node and the second communication node.

7. The wireless communication network of claim 5, wherein the one or more operational parameters include a gain applied to a signal wirelessly communicated between the first communication node and the second communication node.

8. The wireless communication network of claim 5, wherein the one or more operational parameters include a frequency of a signal wirelessly communicated between the first communication node and the second communication node.

9. A method for controlling a process using a wireless communication network, the method comprising:

receiving, using one of one or more communication nodes of the wireless communication network, data indicative of the quality of wireless communications within the wireless communication network between a first communication node of the wireless network and a second communication node of the wireless network;

sending the data indicative of the quality of the wireless communications from the one of the one or more communication nodes to a host device;

processing, using the host device, the data indicative of the quality of the wireless communications at the host device; and

sending a control signal, based on the processing of the data indicative of the quality of the wireless communications, from the host device to one of the one or more communication nodes of the wireless communication network in order to cause the one communication node to which the control signal is sent to modify one or more operating parameters of the wireless communication network so as to affect the quality of the wireless communications within the wireless communication network.

10. The method of claim 9, wherein receiving the data indicative of the quality of the wireless communications within the wireless communication network comprises receiving one or more measurements of environmental factors that affect the quality of the wireless communications within the wireless communication network.

11. The method of claim 9, wherein sending the control signal from the host device to the one communication node causes the one communication node to which the control signal is sent to modify at least one of a signal strength, a gain, or a frequency used by the one communication node in communicating data within the wireless communication network.

12. The method of claim 9, wherein sending the control signal from the host device to the one communication node causes the one communication node to which the control signal is sent to modify the one or more operating parameters so as to change a wireless communication capability between the one communication node and another communication node of the wireless communication network.

13. The method of claim 9, wherein the one communication node at which the data indicative of the quality of the wireless communications within the wireless communication network is received is the one communication node to which the control signal is sent to modify the one or more operating parameters of the wireless communication network.

14. The method of claim 9, wherein the one communication node at which the data indicative of the quality of the wireless communications within the wireless communication network is received is a first communication node, and wherein the one communication node to which the control signal is sent to modify the one or more operating parameters of the wireless communication network is a second communication node.

15. A wireless communication network disposed in a process control system, the wireless communication network comprising:

one or more communication nodes implementing wireless communications within the wireless communication network;

a measuring device communicatively coupled to at least one of the one or more communication nodes, the measuring device measuring one or more parameters that affect the quality of the wireless communications within the wireless communication network; and

a host device communicatively coupled to at least one of the one or more communication nodes, the host device configured to;

receive data indicative of the one or more measured parameters from the measuring device; and

use the received data to determine one or more wireless communication network performance factors that are indicative of the quality of the wireless communications within the wireless communication network and that are affected by the one or more measured parameters.

16. The wireless communication network of claim 15, wherein the measuring device is a first measuring device, wherein the wireless communication network further comprises a second measuring device communicatively coupled to at least one of the one or more communication nodes, wherein the second measuring device measures, at a location distinct from the first measuring device, one or more parameters that affect the quality of the wireless communications within the wireless communication network, and wherein the host device is configured to determine the one or more wireless communication network performance factors further based on data received from the second measuring device.

17. The wireless communication network of claim 16, wherein the one or more parameters measured by the first measuring device are different from the one or more parameters measured by the second measuring device.

18. The wireless communication network of claim 15, wherein the host device includes an operator interface, wherein the host device is configured to:

display information related to the one or more wireless communication network performance factors via the operator interface to illustrate the quality of the wireless communications within the wireless communication network; and

receive, via the operator interface, a command from an operator to adjust at least one operating parameter of the wireless communication network;

cause the at least one operating parameter to be modified so as to affect to the quality of the wireless communications within the wireless communication network.

19. The wireless communication network of claim 15, wherein the host device includes an operator interface, and wherein the host device is configured to display, via the operator interface and based on the one or more wireless communication network performance factors, information illustrating the ability of signals to propagate along particular paths within the wireless communication network.

20. The wireless communication network of claim 19, wherein the host device is configured to display, via the operator interface, the information illustrating the ability of signals to propagate along the particular paths within the wireless communication network in conjunction with indications of positions of structural features of the process control system relative to the particular paths within the wireless communication network.