Industrial automation control system

• US 9,696,692 B2
• Filed: 03/14/2013
• Issued: 07/04/2017
• Est. Priority Date: 04/13/2012
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Chouinard, Julien
• Primary Examiner(s): Everett, Christopher E
• Application Number:
  US13/830,533
• Publication Number:
  US 20130274901A1
• Time in Patent Office: 1,573 Days
• CPC Class Codes: G05B 11/01 electric
• CPC Class Codes: G05B 23/0286 Modifications to the monitored process, e.g. stopping operation or adapting control
• CPC Class Codes: G05B 9/03 with multiple-channel loop, i.e. redundant control systems

Abstract

One or more non-transitory computer-readable storage media having program instructions stored thereon for enhancing an automation environment is provided. When executed by a processor, the program instructions direct the processor to at least identify at least a primary data verification value generated by a primary control process that provides control in an industrial automation environment, and to identify at least a secondary data verification value generated by a secondary control process associated with the primary control process. The program instructions also direct the processor to compare the primary data verification value with at least the secondary data verification value to determine if an error has occurred with respect to the primary control process.

Claims

1. One or more non-transitory computer-readable storage media having program instructions stored thereon for enhancing an automation environment that, when executed by a processor, direct the processor to at least:

identify at least a primary data verification value generated by a primary control process that provides control in an industrial automation environment, wherein the primary control process is configured to run the plurality of control processes;

identify at least a secondary data verification value generated by a secondary control process associated with the primary control process, wherein the secondary control process is configured to run the plurality of control processes;

compare the primary data verification value with at least the secondary data verification value to determine if an error has occurred with respect to a first control of the plurality of control processes of the primary control process; and

in response to determining that the error has occurred;

modify the control provided by the primary control process to prohibit the control of the industrial automation environment by the first control of the primary control process and to allow the control of the industrial automation environment by a remainder of the plurality of control processes of the primary control process.

2. The one or more non-transitory computer-readable storage media of claim 1, wherein the program instructions further direct the processor to at least:

transfer the control of the industrial automation environment by the first control from the primary control process to the secondary control process.

3. The one or more non-transitory computer-readable storage media of claim 1, wherein the program instructions further direct the processor to at least:

perform an emergency shutdown of the industrial automation environment.

4. The one or more non-transitory computer-readable storage media of claim 1, wherein the program instructions further direct the processor to at least:

in response to determining that the error has occurred, modify additional control provided by an additional control process that provides the additional control in the industrial automation environment.

5. The one or more non-transitory computer-readable storage media of claim 1, wherein the data verification values comprise cyclic redundancy check values.

6. The one or more non-transitory computer-readable storage media of claim 1, wherein the processor is of a type from the group comprising:

a programmable automation controller, a programmable logic controller, and a microcontroller.

7. A control system for an industrial automation environment, the control system comprising:

a memory configured to store software instructions;

a processor coupled to the memory, and configured to execute the software instructions directing the processor to at least;

identify at least a primary data verification value generated by a first process of a primary control process that provides control in an industrial automation environment;

identify at least a secondary data verification value generated by a first process of a secondary control process associated with the first process of the primary control process;

identify a third data verification value generated by a second process of the primary control process;

identify a fourth data verification value generated by a second process of the secondary control process associated with the second process of the primary control process;

compare the primary data verification value with at least the secondary data verification value to determine if an error has occurred with respect to the first process of the primary control process;

compare the third data verification value with the fourth data verification value to determine if an error has occurred with respect to the second process of the primary control process; and

in response to determining that the error has only occurred in the first process, transfer the control of the first process from the primary control process to the secondary control process while leaving control of the second process with the primary control process.

8. The control system of claim 7, wherein the processor is further configured to at least:

prohibit the control of the industrial automation environment by the primary control process.

9. The control system of claim 8, wherein the processor is further configured to at least:

perform an emergency shutdown of the industrial automation environment.

10. The control system of claim 7, wherein the processor is further configured to at least:

modify additional control provided by an additional control process that provides the additional control in the industrial automation environment.

11. The control system of claim 7, wherein the data verification values comprise cyclic redundancy check values.

12. The control system of claim 7, wherein the processor is of a type from the group comprising:

a programmable automation controller, a programmable logic controller, and a microcontroller.

13. A method for operating a control system in an industrial automation environment, the method comprising:

identifying at least a primary data verification value generated by a primary control process configured to run a first primary control process and a second primary control process that provide control in an industrial automation environment;

identifying at least a secondary data verification value generated by a secondary control process associated with the primary control process;

comparing the primary data verification value with at least the secondary data verification value to determine if an error has occurred with respect to the first primary control process of the primary control process; and

in response to determining that the error has occurred, modifying the control provided by the primary control process to prohibit the control of the industrial automation environment by the first primary control process and to allow the control of the industrial automation environment by the second primary control process of the primary control process.

14. The method of claim 13, further comprising:

modifying the control provided by the primary control process within a single cycle.

15. The method of claim 13, further comprising:

transferring the control of the industrial automation environment by the first primary control process from the primary control process to the secondary control process.

16. The method of claim 13, further comprising:

performing an emergency shutdown of the industrial automation environment.

17. The method of claim 13, further comprising:

in response to determining that the error has occurred, modifying additional control provided by an additional control process that provides the additional control in the industrial automation environment.

18. The method of claim 13, wherein the data verification values comprise cyclic redundancy check values.