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

• US 9,411,769 B2
• Filed: 01/08/2015
• Issued: 08/09/2016
• Est. Priority Date: 09/19/2006
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Erni, Klaus, Law, Gary Keith, Broom, Doyle Eugene, Burr, Kent Allan, Nixon, Mark J.
• Primary Examiner(s): ABAD, FARLEY J
• Application Number:
  US14/592,354
• Publication Number:
  US 20150127876A1
• Time in Patent Office: 579 Days
• US Class Current: 1/1
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/25139 Use of separate buscouple interface
• CPC Class Codes: G05B 2219/25458 Opto isolation, optical separation
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31129 Universal interface for different fieldbus protocols
• CPC Class Codes: G05B 2219/34421 Termination for each device, enables easy insertion, connection or disconnection
• CPC Class Codes: G06F 13/36 for access to common bus or bus system
• CPC Class Codes: G06F 13/4282 on a serial bus, e.g. I2C bus, SPI bus on daisy chain buses G06F13/4247
• CPC Class Codes: H04L 12/413 with random access, e.g. carrier-sense multiple-access with collision detection [CSMA-CD]
• CPC Class Codes: H04L 12/6418 Hybrid transport
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A disclosed example apparatus includes a first interface to be communicatively coupled to one of a first field device or a second field device. The first interface communicates using a first fieldbus communication protocol when coupled to the first field device and communicates using a second fieldbus communication protocol when coupled to the second field device. The example apparatus includes a communication processor to encode first information received from the one of the first field device or the second field device for communication via a bus using a third communication protocol. The example apparatus includes a second interface communicatively coupled to the communication processor and the bus to communicate the first information to a controller in the process control system. The bus is to use the third communication protocol to communicate second information received from the other one of the first field device or the second field device.

Claims

1. An apparatus, comprising:

a base comprising;

a first physical interface to be communicatively coupled to one of a first field device in a process control system or a second field device in the process control system; and

a second physical interface to be communicatively coupled to a controller in the process control system via a bus; and

a module to be removably attached to the base, the module to communicate with the first field device using a first communication protocol when the first physical interface is communicatively coupled to the first field device, the module to communicate with the second field device using a second communication protocol different than the first communication protocol when the first physical interface is communicatively coupled to the second field device, the module to communicate with the controller via the bus using a third communication protocol, the third communication protocol different from the first and second communication protocols.

2. The apparatus of claim 1, wherein at least one of the first communication protocol or the second communication protocol is a fieldbus protocol.

3. The apparatus of claim 1, wherein the first communication protocol is FOUNDATION fieldbus H1.

4. The apparatus of claim 3, wherein the second communication protocol is Profibus PA.

5. The apparatus of claim 3, wherein the first field device is FOUNDATION fieldbus H1 compliant and is communicatively coupled to the first physical interface in a point-to-point architecture without a segment protector.

6. The apparatus of claim 1, wherein at least one of the first communication protocol or the second communication protocol is WirelessHART.

7. The apparatus of claim 1, wherein at least one of the first communication protocol or the second communication protocol is based on an Internet protocol.

8. The apparatus of claim 1, wherein at least one of the first communication protocol or the second communication protocol is Message Queue Telemetry Transport.

9. The apparatus of claim 1, wherein at least one of the first communication protocol or the second communication protocol implements a tunnel protocol, wherein at least one of the corresponding first field device or the second field device is a safety device.

10. The apparatus of claim 1, wherein the module is to send a first request formatted according to the first communication protocol to the one of the first field device or the second field device and to send a second request formatted according to the second communication protocol to the one of the first field device or the second field device, the communication protocol associated with the one of the first field device or the second field device to be automatically detected based on a response to one of the first or second requests.

11. The apparatus of claim 1, further comprising a diagnostics analyzer to generate diagnostics information corresponding to an analysis of a physical layer and communications between the first physical interface and the one of the first field device or second field device.

12. The apparatus of claim 11, wherein the diagnostics information comprises measurements of at least one of supply voltage, load current, signal level, line noise, or jitter.

13. The apparatus of claim 1, wherein the third communication protocol is to communicate information on the bus from a second module in communication with the bus and in communication with the other one of the first field device or the second field device.

14. An apparatus, comprising:

a base comprising;

a first physical interface to be communicatively coupled to one of a first field device in a process control system or a second field device in the process control system; and

a second physical interface to be communicatively coupled to a controller in the process control system via a bus; and

a module to be removably attached to the base, the module to communicate with the first field device using a first communication protocol when the first physical interface is communicatively coupled to the first field device, the module to communicate with the second field device using a second communication protocol when the first physical interface is communicatively coupled to the second field device, the module to communicate with the controller via the bus using a third communication protocol, the third communication protocol different from the first and second communication protocols, the third communication protocol to communicate information on the bus from a second module in communication with the bus and in communication with the other one of the first field device or the second field device, the first physical interface of the base to be communicatively coupled to a third physical interface of a second base removably attached to the second module to enable peer-to-peer communications between the first and second field devices.

15. A method comprising:

receiving first information at a base having a first physical interface to be communicatively coupled to one of a first field device in a process control system or a second field device in the process control system;

at a module removably attached to the base, encoding the first information for communication using a first communication protocol, the first information communicated to the module from the first field device using a second communication protocol when the first physical interface is coupled to the first field device, the first information communicated to the module from the second field device using a third communication protocol different than the second communication protocol when the first physical interface is coupled to the second field device, the first communication protocol different from the second and third communication protocols; and

communicating the encoded first information from the module, via a second physical interface of the base, to a controller via a bus using the first communication protocol.

16. The method of claim 15, wherein the second communication protocol is Profibus PA and the third communication protocol is FOUNDATION fieldbus H1.

17. The method of claim 16, further comprising automatically detecting the second communication protocol or the third communication protocol associated with the one of the first field device or the second field device when the one of the first field device or the second field device is communicatively coupled to the first physical interface.

18. An apparatus, comprising:

a first interface to be communicatively coupled to one of a first field device in a process control system or a second field device in the process control system, the first interface to communicate using a first fieldbus communication protocol when coupled to the first field device and to communicate using a second fieldbus communication protocol different than the first fieldbus communication protocol when coupled to the second field device;

a communication processor communicatively coupled to the first interface, the communication processor to encode first information received from the one of the first field device or the second field device for communication via a bus using a third communication protocol different from the first and second fieldbus communication protocols; and

a second interface communicatively coupled to the communication processor and the bus to communicate the first information via the bus using the third communication protocol to a controller in the process control system, wherein the bus is to use the third communication protocol to communicate second information received from the other one of the first field device or the second field device.

19. The apparatus of claim 18, wherein the first field device is Profibus PA compliant and is communicatively coupled to the first interface in a point-to-point architecture without a DP/PA segment coupler.