Title of Invention

"INTERFACE MODULE FOR USE WITH A FIELDBUS DEVICE NETWORK AND WITH INTERNET AND NON-INTERNET BASED PROCESS CONTROL NETWORKS"

Abstract An interface module is operatively connected to a Fieldbus process control network and to at least one non-Fieldhus process control network to facilitate the exchange of process control information between the networks. The interface module stores a database in which the process control parameters of the function blocks in the field devices of the Fieldbus process control network are mapped to corresponding process control parameters of the non-Fieldbus process control network. Once the Fieldbus process control parameters are mapped to the non-Fieldbus process control parameters, the interface module is adapted to transmit request messages on the Fieldbus process control network to the Fieldbus field devices for the current values of the process control parameters, receive response messages from the Fieldbus field devices, and store the current values of the process control parameters in the database. The interface module may also function in the other direction to map non-Fieldbus process control parameters to corresponding Fieldbus process control parameters.
Full Text INTERFACE MODULE FOR USE WITH A FIELDBUS DEVICE NETWORK
AND WITH INTERNET AND NON-INTERNET BASED PROCESS
CONTROL NETWORKS
FIELD OF THE INVENTION
[0001] The present invention relates generally to process-control systems
and, more particularly, to an interface module for exchanging data between a Fieldbus
device network and Internet and non-Internet based process control networks.
DESCRIPTION OF THE RELATED ART
[0002] Process control systems, like those used in chemical, petroleum or
other processes, typically include at least one centralized process controller
communicatively coupled to at least one host or operator workstation and to one or
more field devices via analog and/or digital buses or other communication lines or
channels. The field devices, which may be, for example, valves, valve positioners,
switches, transmitters (e.g., temperature, pressure and flow rate sensors), etc. perform
functions within the process such as opening or closing valves and measuring process
parameters. The process controller receives signals indicative of process
measurements made by the field devices and/or other information pertaining to the
field devices via an input/output (I/O) device, uses this information to implement a
control routine and then generates Control signals which are sent over the buses or
other communication channels via the input/output device to the Field devkes to
control the operation of the process. Information from the "field devices and the
controller is typically made available to one or more applications executed by the
operator workstation to enable an operator to perform any desired function with
respect to the process, such as viewing the current state of the process, modifying the
operation of the process, configuring the process, documenting the process, etc.
[0003] In the past decade or so, smart field devices including a
microprocessor and a memory have become prevalent in the process control industry.
In addition to performing a primary Junction within the process, smart field devices
may store data pertaining to the device, communicate with the controller and/or other
devices in a digital or combined digital and analog format, and perform secondary
tasks such as self-calibration, identification, diagnostics, etc. A number of standard
and open smart device communication protocols such as the HART®, PROFIBUS®,
Actuator Sensor Interface (hereinafter "AS-Interface" or "ASI"), WORLDFIP®,
Device-Net®, CAN, and FOUNDATION™ Fieldbus (hereinafter "Fieldbus") protocols,
and have been developed to enable smart field devices made by different
manufacturers to be used together within the same process control network. These
process control networks may be implemented using Internet-based protocols, such as
FOUNDATION™ Fieldbus over High Speed Internet, Modbus TCP, ProfiNet and OPC,
and non-Internet based protocols, such as Modbus, Profibus DP, DeviceNet, HART®,
CANOpen, and the like.
[0004] One such standard communication protocol for smart field devices is
the Profibus DP protocol. The Profibus DP protocol defines a message structure that
controllers will recognize and use regardless of the types of networks over which they
communicate. It establishes a common format for the layout and content of message
fields. Profibus DP defines a process for the controllers to request access to other
devices, for the controllers and devices to respond to requests, and for error detection
and reporting. During communications on a Profibus DP network, the protocol
determines how each controller or device will know its device address, recognize a
message addressed to it, determine the kind of action to be taken based on a service
code contained in the message, and extract any data or other information contained in
the message. If a reply is required, the slave device will construct the reply message
and send it to the master device using the Profibus DP protocol. The Profibus DP
protocol is known in the art and is described in detail in numerous articles, brochures
and specifications published, distributed and available from, among others,
manufacturers of devices using the Profibus DP protocol. As a result, the details of
the Profibus DP communication protocol will not be described in detail except to the
extent they relate to the present invention.
[0005] Profibus DP employs a master-slave query-response cycle for
exchanging information between controllers and field devices. Each device is
assigned an address ranging between 0 and 125. One device, the master, initiates
transactions, such as queries, set point changes, diagnostics, and the like, by
transmitting a message addressed to another device, the slave. Under the Profibus DP
protocol, the message transmitted by the master is formatted to include the device
address of the slave device, a service code defining the requested action, any data to
be sent to the slave device, and error-checking information. The slave device detects
and receives the message from the master based on the address in the message, and
processes the transaction or service indicated by the service code in the message.
After processing the transaction or performing the requested service, the slave
transmits a response message constructed using the Profibus DP protocol and
containing information confirming the action taken, any data to be returned to the
master, and error-checking information. In addition to individual messages, the
master may send messages to a defined group of slave devices (multi-cast messages),
or may broadcast a message to all connected slaves. The master transmits broadcast
and multi-cast messages as global control messages to the slaves using address 127
and, in the case of multi-cast messages, an optional group number for a targeted group
of slave devices. While the slaves respond to messages addressed to them
individually, the slaves do not respond to broadcast or multi-cast messages from the
master device.
[0006] Data is exchanged between devices in the Profibus DP network
using service access points. Each Profibus DP device has a profile including the
specified set of process control parameters associated with device, and each process
control parameter used in the Profibus DP network is assigned a corresponding
service access point from a range of available service access points. The devices in
the Profibus DP network are configured to store and exchange the process control
parameters according to their assigned service access points. In order to obtain the
value of a process control parameter from a slave device, a master device formats and
transmits a request message including the address of the slave device and the service
access point for the process control parameter. Upon receiving the request message,
the slave device reads the current value for the service access point, and formats and
transfers a response message with the service access point and its stored value.
Another example of a non-Internet based protocol is the Modbus protocol, which is
described more fully in co-pending U.S. Patent Application Serial No. 10/354,525
filed on January 30, 2003 from which the present application-claims priority and the
specification of which is expressly incorporated herein by reference.
|0007] Generally speaking, the Fieldbus protocol is an all-digital, serial,
two-way communication protocol that provides a standardized physical -interface to a
two-wire loop or bus that interconnects field devices. The Fieldbus protocol provides,
in effect, a local area network for field devices within a process, which enables these
field devices to perform process control functions (using function blocks) at locations
distributed throughout a process facility and to communicate with one another before
and after the performance of these process control functions to implement an overall
control strategy. The Fieldbus protocol is known in the art and is described in detail
in numerous articles, brochures and specifications published, distributed, and
available from, among others, the Fieldbus Foundation, a not-for-profit organization
headquartered in Austin, Texas. As a result, the details of the Fieldbus
communication protocol will not be described in detail herein except to the extent
they relate to the present invention.
[0008] A Fieldbus process control network may include one or more
interconnected Fieldbus segments, with each segment having one or more field
devices, linked together via a bus. For communication to occur, one of the devices on
each segment of the bus operates as a link active scheduler (LAS) that actively
schedules and controls communication on the associated segment of the bus. The
LAS for each segment of the bus stores and updates a communication schedule (a link
active schedule) containing the times that each function block of «ach device is
scheduled to start periodic communication activity on the bus and the length of time
for which this communication activity is to occur. The LAS also controls
asynchronous communication activities that may occur when no synchronous
communication is taking place on the bus segment. During the time that synchronous
communication is not occurring, each field device is allowed, in rum upon receipt of a
pass token message from the LAS, to transmit alarm data, view data, etc. in an
asynchronous manner.
[0009] Under the Fieldbus protocol, field devices are able to communicate
with each other over a bus using unique addresses that are assigned to each field
device. The field devices are attached to nodes of the bus, and each node has a
designated physical address that identifies the field device attached thereto for use in
communicating with the other field devices in the process control network. The
unique address for the field device is included in the messages published by the
device on the bus. The field device or devices to which the messages are published
are configured to listen to the bus segment to which it is connected for messages
containing the address of the publishing field device. When the subscribing field
devices detect messages with the address of the publishing field device, they decode
and process the messages as necessary to effect process control.
[0010] Field devices are able to publish or transmit data and messages over
the bus using one of three types of virtual communication relationships (VCRs)
defined in each field device. A client/server VCR is used for queued, unscheduled,
user initiated, one-to-one, communications between devices on the bus. A field
device may use a client/server VCR when it receives a pass token message from an
LAS to send a request message to another device on the bus. The requester is called
the "client" and the device that receives the request is called the "server." The server
sends a response when it receives a pass token message from the LAS and processes
the client's request. The client/server VCR is used, for example, to effect operator
initiated requests such as set point changes, tuning parameter access and changes,
alarm acknowledgments, and device uploads and downloads.
[0011] A report distribution VCR is used for queued, unscheduled, user
initiated, one-to-many communications. For example, when a field device with an
event or a trend report receives a pass token from an LAS, that field device sends its
message to a "group address" defined in the device. Devices that are configured to
listen on that VCR will receive the report. The report distribution VCR type is
typically used by Fieldbus devices to send alarm notifications to operator consoles.
[0012] Finally, a publisher/subscriber VCR type is used for buffered, oneto-
many communications. Buffered communications are ones that store and send
only the latest version of the data and, thus, new data completely overwrites previous
data. Function block outputs, for example, comprise buffered data. A "publisher"
field device publishes or broadcasts a message using the publisher/subscriber VCR
type to all of the "subscriber" field devices on the bus when the publisher device
receives a compel data message from the LAS or from a subscriber device. The
publisher/subscriber relationships are predetermined and are defined and stored within
each field device. Like Profibus DP and Fieldbus, other protocols provide
communication strategies to allow smart field devices to exchange information and
implement process control strategies.
[0013] As previously indicated, non-Internet based protocols, such as the
Profibus DP, Modbus and Fieldbus protocols, and Internet-based protocols have been
in use in process control systems for the last decade or so. As a result, conditions may
arise wherein process control networks using the Fieldbus protocol may co-exist with
process control networks using other protocols in the same plant or facility. For
example, an installation having an incumbent process control system operating under
the Profibus DP protocol may convert a portion of the process control network to
operate under the Fieldbus protocol in order to implement a particular control strategy
or capability that is supportable by the Fieldbus protocol. However, despite the
partial conversion, the Profibus DP portion of the process control network may still
require information and data from the Fieldbus portion of the process control network.
As a further example, a plant or facility with an existing process control network
operating under the Profibus DP protocol may be expanded to include additional
processes having process control networks operating under the Fieldbus protocol, or
vice versa. Moreover, the facility may include other processes having process control
networks operating under Internet-based protocols. As with the previous example, it
may be necessary to communicate data and information between the Fieldbus
network, the Profibus DP network and the Internet-based network. In current
implementations, data cannot be communicated between these divergent process
control networks. Therefore, a need exists for an interface module that may be
connected between process control networks using differing communication protocols
to allow information and data from the various networks to be communicated between
the devices in the networks.
SUMMARY OF THE INVENTION
[0014] An interface module is operatively connected to a Fieldbus process
control network and to at least one non-Fieldbus process control network to facilitate
the exchange of process control information between the networks. The interface
module stores a database in which the process control parameters of the function
blocks in the field devices of the Fieldbus process control network are mapped to
corresponding process control parameters of the non-Fieldbus process control
network. Once the Fieldbus process control parameters are mapped to the non-
Fieldbus process control parameters, the interface module is adapted to transmit
request messages on the Fieldbus process control network to the Fieldbus field
devices for the current values of the process control parameters, receive response
messages from the interface module containing the current values of the process
control parameters from the Fieldbus field devices, and store the current values of the
process control parameters in the service access point database. The interface module
may also function in the other direction to map non-Fieldbus process control
parameters to corresponding Fieldbus process control parameters.
[0015] Field devices in the non-Fieldbus process control network may
obtain the values of the Fieldbus process control parameters by transmitting request
messages to the interface module for the current values of the non-Fieldbus process
control parameters to which the Fieldbus process control parameters have been
mapped. Upon receiving the requests, the interface module reads the database «ntry
corresponding to the non-Fieldbus process control parameter to obtain the value of the
Fieldbus process control parameter. The interface module formats and transmits a
response to the requesting non-Fieldbus field device containing the non-Fieldbus
process control parameter and value of the corresponding Fieldbus process control
parameter from the database. In order to configure the database to associate the
Fieldbus process control parameters with the non-Fieldbus process control
parameters, the interface module may include an Internet connection to which a user
interface, such as a personal computer, may be connected. Web server software in the
interface module and web browser software at the user interface may be used to
provide a graphical interface for the service access point database configuration
process.
[0016] In one aspect, the invention is directed to an interface module for use
in a process control system including a Fieldbus process control network having a
plurality of Fieldbus field devices and at least a first non-Fieldbus process control
network having a plurality of non-Fieldbus field devices. The interface module may
operatively connect the Fieldbus process control network to the first non-Fieldbus
process control network and may be adapted to facilitate the exchange of process
control information between the Fieldbus process control network and the first non-
Fieldbus process control network. The interface module may include a Fieldbus I/O
module operatively connected to the Fieldbus process control network and adapted to
transmit and receive Fieldbus protocol messages on the Fieldbus process control
network, a first non-Fieldbus I/O module operatively connected to the first non-
Fieldbus process control network and adapted to transmit and receive messages
communicated using a protocol other than the Fieldbus protocol on the first non-
Fieldbus process control network, and a controller operatively connected to the
Fieldbus I/O module and the first non-Fieldbus I/O module, and including a processor
and a memory operatively connected to the processor. The controller may be
programmed to cause the Fieldbus I/O module to transmit messages to and receive
messages from Fieldbus field devices on the Fieldbus process control network, and to
cause the first non-Fieldbus I/O module to transmit messages to and receive messages
from non-Fieldbus field devices on the first non-Fieldbus process control network.
10017] In another aspect, the invention is directed to a method of
exchanging process control information between a Fieldbus process control network
having a plurality of Fieldbus field devices and a non-Fieldbus process control
network having a plurality of non-Fieldbus field devices. The method may include
operatively connecting an interface module to the Fieldbus process control network
and to the non-Fieldbus process control network. The interface module may be
configured to transmit and receive Fieldbus protocol messages on the Fieldbus
process control network and to transmit and receive non-Fieldbus protocol messages
on the non-Fieldbus process control network. The method may also include storing in
the interface module a database wherein at least one process control parameter of one
of the process control networks is associated with a process control parameter of the
other of the process control networks, causing the interface module to request a
current value of the at least one process control parameter from a corresponding one
of the field devices in the one of the process control networks, and storing the current
value of the at least one process control parameter of the one of the process control
networks in the database with the associated process control parameter of the other of
the process control networks. The method may further include causing the interface
module to transmit a response message to one of the field devices of the other of the
process control networks with the current value of the at least one process control
parameter of the one of the process control networks and the process control
parameter of the other of the process control networks in response to receiving a
request message from the one of the field devices of the other of the process control
networks at the interface module for the current value of the associated process
control parameter of the other of the process control networks.
[0018] In a further aspect of the invention, an interface module is provided
for use in a process control system including a Fieldbus process control network
having a plurality of Fieldbus field devices and a Profibus DP process control network
having a plurality of Profibus DP field devices. The interface module may
operatively connect the Fieldbus process control network to the Profibus DP process
control network and may be adapted to facilitate the exchange of process control
information between the Fieldbus process control network and the Profibus DP
process control network. The interface module may include a Fieldbus I/O module
operatively connected to the Fieldbus process control network and adapted to transmit
and receive Fieldbus protocol messages on the Fieldbus process control network, a
Profibus DP I/O module operatively connected to the Profibus DP process-control
network and adapted to transmit and receive Profibus DP protocol messages on the
Profibus DP process control network, and a controller operatively connected to the
Fieldbus I/O module and the Profibus DP I/O module, with the controller including a
processor and a memory operatively connected to the processor.
[0019] The controller of the interface module may be programmed to store
in the memory a service access point database wherein at least one Fieldbus process
control parameter of the Fieldbus process control network is associated with a
Profibus DP service access point of the Profibus DP process control network, and be
programmed to cause the Fieldbus I/O module to request a current value of the at least
one Fieldbus process control parameter from a corresponding one of the Fieldbus field
devices. The controller may further be programmed to store the current value of the
at least one Fieldbus process control parameter in the service access point database
with the associated Profibus DP service access point, and may be programmed to
cause the Profibus DP I/O module to transmit a response message to one of the
Profibus DP field devices with the current value of the at least one Fieldbus process
control parameter and the associated Profibus DP service access point in response to
receiving a request message from the one of the Profibus DP field devices at the
Profibus DP I/O module for the current value of the associated Profibus DP service
access point.
[0020] According to another aspect of the invention, a process control
system includes a Fieldbus process control network having a plurality of Fieldbus
field devices, a Profibus DP process control network having a plurality of Profibus
DP field devices, and an interface module operatively connecting the Fieldbus process
control network to the Profibus DP process control network which may be adapted to
facilitate the exchange of process control information between the Fieldbus process
control network and the Profibus DP process control network. The interface module
may include a Fieldbus I/O module operatively connected to the Fieldbus process
control network and adapted to transmit and receive Fieldbus protocol messages on
the Fieldbus process control network, a Profibus DP I/O module operatively
connected to the Profibus DP process control network and adapted to transmit and
receive Profibus DP protocol messages on the Profibus DP process control network,
- and a controller operatively connected to the Fieldbus I/O module and the Profibus
DP I/O module which may include a processor and a memory operatively connected
to the processor.
{0021] The controller may be programmed to store in the memory a service
access point database wherein at least one Fieldbus process control parameter of the
Fieldbus process control network is associated with a Profibus DP service access
point of the Profibus DP process control network, and to cause the Fieldbus I/O
module to request a current value of the at least one Fieldbus process control
parameter from a corresponding one of the Fieldbus field devices. The controller may
further be programmed to store the current value of the at least one Fieldbus process
control parameter in the service access point database with the associated Profibus DP
service access point, and to cause the Profibus DP I/O module to transmit a response
message to one of the Profibus DP field devices with the current value of the at least
one Fieldbus process control parameter and the associated Profibus DP service access
point in response to receiving a request message from the one of the Profibus DP field
devices at the Profibus DP I/O module for the current value of the associated Profibus
DP service access point.
|0022] According to a still further aspect of the invention, a method of
exchanging process control infprmation between a Fieldbus process control network
having a plurality of Fieldbus field devices and a Profibus DP process control network
having a plurality of Profibus DP field devices may include the steps of operatively
coupling an interface module to the Fieldbus process control network and to the
Profibus DP process control network, the interface module being adapted to transmit
and receive Fieldbus protocol messages on the Fieldbus process control network and
to transmit and receive Profibus DP protocol messages on the Profibus DP process
control network, and storing in the interface module a service access point database
wherein at least one Fieldbus process control parameter of the Fieldbus process
control network is associated with a Profibus DP service access point of the Profibus
DP process control network. The method may further include causing the interface
module to request a current value of the at least one Fieldbus process control
parameter from a corresponding one of the Fieldbus field devices, and storing the
current value of the at least one Fieldbus process control parameter in the service
access point database with the associated Profibus DP service access point. Still
further, the method may include the step of causing the interface module to transmit a
response message to one of the Profibus DP field devices with the-current value of the
at least one Fieldbus process control parameter and the associated Profibus DP service
access point in response to receiving a request message from the one of the Profibus
DP field devices at the interface module for the current value of the associated
Profibus DP service access point.
[0023] The features and advantages of the invention will be apparent to
those of ordinary skill in the art in view of the description of the embodiments, which
is made with reference to the drawings, a brief description of which is provided
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024J Fig. 1 is a block diagram of a process control system having a
Profibus DP process control network connected to a Fieldbus process control network
by an interface module.
[0025] Fig. 2 is a functional block diagram of the interface module of Pig.
1.
[0026] Fig. 3 is a portion of service access point database mapping Fieldbus
process control parameters to Profibus DP service access points.
[0027] Fig. 4 is a functional block diagram of an alternative embodiment of
the interface module of Fig. 1.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0028] Although the following text sets forth a detailed description of
numerous different embodiments of the invention, it should be understood that the
legal scope of the invention is defined by the words of the claims set forth at the end
of a patent. The detailed description is to be construed as exemplary only and does
not describe every possible embodiment of the invention since describing every
possible embodiment would be impractical, if not impossible. Numerous alternative
embodiments could be implemented, using either current technology or technology
developed after the filing date of this provisional patent application, which would still
fall within the scope of the claims defining the invention.
[0029] It should also be understood that, unless a term is expressly defined
in this patent using the sentence "As used herein, the term ' ' is hereby defined
to mean..." or a similar sentence, there is no intent to limit the meaning of that term,
either expressly or by implication, beyond its plain or ordinary meaning, and such
term should not be interpreted to be limited in scope based on any statement made in
any section of this patent (other than the language of the claims). To the extent that
any term recited in the claims at the end of this patent is referred to in this patent in a
manner consistent with a single meaning, that is done for sake of clarity only so as to
not confuse the reader, and it is not intended that such claim term by limited, by
implication or otherwise, to that single meaning. Finally, unless a claim element is
defined by reciting the word "means" and a function without the recital of any
structure, it is not intended that the scope of any claim element be interpreted based
on the application of 35 U.S.C. § 112, sixth paragraph.
[0030] Referring now to Fig. 1, a process control system 10 may include a
non-Internet based protocol process control network 12 connected to a Fieldbus
process control network 14, and to an Internet-based protocol process control network
17 by an interface module 16. The non-Internet based process control network 12
may include a host device or controller 18 connected to a plurality of field devices 20-
24 and one or more user interfaces 26. In this system, the host 18 may be used to
implement process control in the non-Internet based process control network 12 and
serve as a master device initiating transactions that are received by the devices 20-24
and user interface 26, depending on the requirements of the process control network
and non-Internet based protocol under which the network 12 may be operating. The
devices 20-24 and user interface 26 may respond by supplying requested data to the
host 18, or by taking action requested by the query.
[0031] The Fieldbus process control network 14 may include a host or
controller 28 connected to a number of other devices such as a program logic
controller (PLC) 30, a number of controllers 32, another host device 34 and a set of
field devices 36-66 via a two-wire Fieldbus loop or bus 68. The Fieldbus process
control network 14 may include different sections or segments, 68a, 68b, 68c and-68d.
Some segments, such as segment 68b, may be connected directly to the bus 68, while
other segments, such as segments 68a and 68c, may be connected to the bus 68 by
bridge devices 70, 74. Still further, the Fieldbus process control network 14 may
include segments, such as segment 68d, connected to the Fieldbus process control
network 14 by the interface module 16. Each of the sections 68a, 68b, 68c and 68d
interconnects a subset of the devices to enable communications between the devices
in a manner previously described. For communication to occur, one of the devices on
each segment of the bus 68 operates as the link active scheduler (for example,
controller 28 and devices 36, 48, 56 and 64) that actively schedules and controls
communication on the associated segment of the bus 68.
[0032] The non-Internet based network 12 is connected to the Fieldbus
network 14 by the interface module 16. The interface module 16 is connected to the
non-Internet based network 12 via an input/output (I/O) port configured to be
protocol-compatible with the non-Internet based process control network 12, and to
nodes on one or more of the segments 68a, 68b, 68c and 68d of the Fieldbus network
14 via Fieldbus-compatible I/O ports. To facilitate communications to andlrorn the
interface module 16 in the non-Internet based network 12, the interface module 16
may be assigned a device address within the protocol of the network 12, and the
interface module 16 may be configured so that the devices 18-26 ^an format and
transmit messages for the interface module 16, and the interface module 16 can
receive, identify and process the messages, perform the requested action, and transmit
response messages to the devices 18-26 via the protocol-compatible I/O port using the
protocol of the network 12 in the same manner as other devices 18-26 of the network
12.
|0033] The interface module 16 may also be configured as a link master
device of the Fieldbus process control network 14 so that the interface module 16 may
function as the link active scheduler for one or more of the segments of the Fieldbus
process control network 14 attached thereto. Moreover, as previously discussed, the
interface module 16 may also function as a bridge device to facilitate communications
between a segment, such as segment 68d, that may not be connected directly to the
bus 68 and/or the other segments 68a, 68b and 68c of the Fieldbus process control
network 14.
[0034] As with the non-Internet based network 12, the interface module 16
is capable of communicating on the segments 68a, 68b, 68c and 68d of the bus 68 to
which it is connected via the Fieldbus I/O ports. The interface module 16 is assigned
a Fieldbus device address so that the interface module 16 is recognized by the devices
36-66 on the segments 68a, 68b, 68c and 68d to which it is attached. The link master
schedules in the LAS devices 36, 48, 56 and 64 are configured so that pass token
messages will be transmitted to the interface module 16 during the asynchronous
periods of the link master schedules. The VCRs in the devices 36-66 and at the
interface module 16 are configured so that the interface module 16 may transmit
messages to the field devices 36-66 requesting the values of the process control
parameters for which the interface module 16 is configured to store, and the field
devices 36-66 may transmit response messages to the interface module 16 containing
the current values of the requested Fieldbus process control parameters.
[0035] The Internet-based protocol process control network 17 may include
one or more host devices or controllers 76 connected to a plurality of field devices 78-
82 and one or more user interfaces 84 that may communicate using the Internet-based
protocol under which the process control network 17 operates, hi the process control
network 17, the host device(s) 76 and field devices 78-82 may be configured to
implement a process control strategy using the Internet-based protocol associated with
the process control network 17. The Internet-based process control network may also
be connected to the non-Internet based process control network 12 and/or the Fieldbus
process control network 14 by the interface module 16. The interface module 16 is
connected to the Internet-based process control network 17 via an Internet-compatible
input/output (I/O) port, which may allow the devices 76-84 of the network 17 to
communicate with the interface module 16, and to exchange information with the
other process control networks 12, 14 in a manner described more fully below. As
with the other networks 12, 14, the interface module 16 may be assigned a device
address within the protocol of the network 17 to facilitate communications to and
from the interface module 16 and the Internet-based network 17. Configured in this
way, the interface module 16 can receive, identify and process the messages, perform
the requested action, and transmit response messages to the devices 76-84 via the
Internet-compatible I/O port using the protocol of the network 17 in the same manner
as other devices 76-84 of the network 17.
[0036] In order to communicate with the Internet-based network 17, and to
configure the interface module 16 and display data compiled therein, the interface
module 16 may be programmed with web server software. Configuration of the
interface module 16 may be accomplished over the Internet-compatible I/O port using
the standard web browser software available in any personal computer, such as user
interface 86. Web pages provided by the web server software of the interface module
16 to the web browser software of the user interface 86 allow a process monitor or
operator to map process control parameters of the devices 36-66 of the Fieldbus
network 14 to corresponding parameters for use in the Internet and non-Internet based
networks. The web pages may also allow the monitor or operator to view the current
values of the process control parameters from the interfaced networks that may be
mapped to corresponding parameters in one or more of the other interfaced networks
and stored in the interface module 16.
|0037J Referring now to Fig. 2, the interface module 16 may include a
controller 90 connected to memory 92, a non-Internet based protocol-compatible I/O
module 94, Fieldbus I/O modules 96-102, and Internet-compatible I/O module 104.
The controller 90 may be embodied in hardware that is commercially available, such
as in a 16 or 32 bit, 16 megahertz (MHZ) 80C960SA microcontroller, which is
commercially available from Intel, or may be embodied in any other suitable
microcontroller. The controller 90 may include a processor 106 that is
communicatively coupled to a memory 108 via a bus 110. The memory 108 of the
controller 90 may be random access memory (RAM), read-only memory (ROM),
such as a semi-conductor ROM, or any suitable combination thereof. Alternatively or
additionally, the memory 108 may include any one of, or any suitable combination of,
an electrically erasable programmable read-only memory (EEPROM), a one-time
programmable electrically programmable read-only memory (OTP EPROM), a static
random access memory (SRAM), flash or any other suitable memory element may be
externally connected to the processor 106 of the controller 90. Furthermore, the
memory(ies) may be embodied in other computer-readable media such as optical
media, e.g., CDs, rewritable CDs, DVDs and the like, or magnetic media, e.g., floppy
discs, hard drives, zip discs and the like.
[0038] The non-Internet I/O module 94 connects the controller 90 to the
non-Internet based protocol network 12 using, for example, an RS485 serial port, a
port for an Ethernet connection, such as a standard RJ, 45/10/1 OObt connector, or any
other suitable connection to the particular non-Internet based protocol network known
in the art. The non-Internet I/O module 94 is configured to communicate with the
host 18, field devices 20-24 .and user interface 26 using the corresponding non-
Internet based protocol. For example, where the non-Internet based network 12 is a
Profibus DP network, the non-Internet I/O module 94 may be configured to receive
messages transmitted on the Profibus DP network 12, and to detect messages
transmitted by the host 18 or other master devices containing the Profibus DP address
assigned to the interface module 16. Once detected, the non-Internet I/O module 94
may be capable of extracting and, if necessary, reformatting the data contained in the
message and transferring the information to the controller 90 for executing the service
request from the host 18. The non-Internet I/O module 94 may be further configured
to receive data from the controller 90, which may be provided in response to a service
request from the host 18, formatting an appropriate Profibus DP protocol message,
and transmitting the message through the non-Internet I/O module 94 over the
Profibus DP network 12.
[0039] Those skilled in the aft will understand that the non-Internet I/O
module 94 may be implemented in any appropriate manner to facilitate
communications between the devices of the non-Internet based network 12 and the
interface module 16 using the corresponding protocol. For example, the non-Internet
I/O module 94 may be implemented as software within the interface module 16 that
may be programmed to communicate between the network 12 and interface module
16 using the non-Internet protocol implemented in the network 12. In such an
implementation, the I/O module 94 may be programmed or reprogrammed at the
interface module 16 via a download of programming instructions from an external
storage device. Alternatively, the I/O module 94 may be reprogrammed and
reconfigured by downloading code from the user interface 86 connected to the
interface module 16 via the Internet. Still further, the interface module 16 may be
preprogrammed with the software for multiple non-Internet based protocols that may
be used in process control networks to which the interface module 16 may be
connected. Once the protocol of the process control network 12 to which the interface
module 16 is to be connected is identified, the interface module 16 may be configured
to execute the software for the particular one of the available protocols to enable the
non-Internet I/O module 94 to communicate with the devices 18-26 of the process
control network 12 using the appropriate protocol. As a further alternative, the I/O
module 94 may be modular such that the physical module for one non-Internet
protocol may be disconnected and removed from the interface module 16 and
replaced with another physical module configured to communicate using the
appropriate protocol for the process control network 12 to which the interface module
16 is to be connected.
[0040] In a similar manner as the non-Internet I/O module 94, the Fieldbus
I/O modules 96-102 connect the controller 90 to the Fieldbus segments 6°8a, 68b, 68c
and 68d using, for example, HI I/O cards, and facilitate communications between the
controller 90 and the Fieldbus field devices 36-66. One or more of the Fieldbus I/O
modules 96-102 are attached to nodes of the segments 68a, t>8b, 68c and 68d,
respectively, and the interface module 16 is assigned a Fieldbus address to be used for
communicating with the field devices 36-66 connected to the segment 68a, €8b, 68c,
and 68d. The link active schedules are configured so that pass token messages for the
interface module 16 are transmitted by the LAS field devices 36,48, 56 and-64 during
the asynchronous communications periods of the schedules. Fieldbus I/O modules
96-102 detect the pass token messages for the interface module 16, and any other
messages for the interface module 16 transmitted on the segments 6Sa, 68b, 68c and
68d, and transmit the information in the messages to the controller 90 for processing.
When the interface module 16 communicates with the field devices 36-66 of the
Fieldbus network 14, controller 90 causes the Fieldbus I/O modules 96-102 to format
Fieldbus protocol messages, and to transmit the messages on the appropriate Fieldbus
segment 68a, 68b, 68c or 68d.
[0041] The Internet I/O module 104 may connect the interface module 16 to
an Internet-based process control network, such as process control network 17, and/or
to a user interface 86. The interface module 16 may be programmed with standard'
web server software so that a computer with a web browser, such as the user interface
86, connected thereto may be used to configure the interface module 16 and to view
process control information stored therein. An Internet I/O module 104 is connected
to the controller 90 and may include a port for an Ethernet connection, such as, for
example, a standard RJ 45/10/1 OObT connector. Alternatively, the Internet I/O
module 104 may include an appropriate port for any other type of Internet connection,
and may even by configured for wireless communications capabilities for
communicating with the Internet-based process control network 17 and/or the user
interface 86. Depending on the particular implementation of the interface module 16,
the Internet connection may be used to connect the interface module 16 directly to the
user interface 86 or, alternatively, to a local area network wherein multiple networked
devices with web browser software may be provided with access to the information
contained in the interface module 16. Moreover, the user interface 86 may be a
device within the Internet-based process control network 17. Similar as for the non-
Internet I/O module 94, the interface module 16 may be programmed or
reprogrammed to cause the Internet I/O module 104 to communication with the
Internet process control network 17 using the associated Internet-based
communications protocol.
[0042] In some implementations, the interface module 16 is configured to
obtain and store process control information from the Fieldbus process control
network 14, and to provide the stored Fieldbus process control information to the
process control networks 12, 17 upon receiving requests from the devices of the
process control networks 12, 17. In order to allow devices in the process control
networks 12, 17 to request the values of process control parameters used in the
Fieldbus network 14, the process control parameters used in the Fieldbus network 14
may be mapped to corresponding parameters or data structures in the process control
networks 12, 17, with the values of the Fieldbus process -control parameters being
stored at the interface module 16 in a database or databases in memory 108. Once the
Fieldbus process control parameters are mapped to data structures in the process
control networks 12, 17, the devices of the process control networks 12, 17 may be
configured to transmit messages to the interface module 16 using the corresponding
communication protocol and requesting the values of the data structures to which the
Fieldbus process control parameters are mapped. Upon receiving the request
messages at the interface module 16, the processor 106 of the controller 90 looks up
values stored in the database in memory 108 corresponding to the data structure in the
request messages, and causes the corresponding I/O module 94, 104 to format and
transmit protocol-specific response messages with the data structure and
corresponding Fieldbus process control parameter values. The requesting devices
receive and process the response messages in the same manner as any response
message transmitted by a device of the corresponding process control network 12,17.
[0043] As previously discussed, Fieldbus process control parameters are
mapped to corresponding data structures for the process control networks 12, 17 in
databases stored in the memory 108 of the interface module 16. Yig. 3 illustrates one
example of a database 120 that may be constructed at the interface module 16 and
stored in the memory 108 of the controller 90 mapping Fieldbus process control
parameters to Profibus DP service access points. In this example, the non-Internet
based process control network 12 may be a Profibus DP process control network as
known in the art. For each Fieldbus process control parameter that is mapped to a
Profibus DP service access point 122, the service access point database 120 may
include a segment identifier 124, a device identifier 126, a function block identifier
128 and a parameter identifier 130, along with a current value 132 of the Fieldbus
process control parameter. The example of Fig- 3 illustrates one implementation of
the interface module 16 in accordance with the invention wherein the master devices
of the Profibus DP process control network 12, such as the host 18, may be able to
obtain, via the interface module 16, the output value and the output status of some or
all of the function blocks of the Fieldbus process control network 14. In the service
access point database 120 of Fig. 3, service access points in the range of 45,001-
45,999 may be mapped to store the current output status of various Fieldbus function
blocks, and service access points in the range of 47,001-47,999 may be mapped to
store the output values of the various Fieldbus function blocks. For example, in the
database 120 of Fig. 3, the output status of a thermal transducer TT-01-1 of device
848-01 on segment 1 may be mapped to Profibus DP service access point 45,001,
while the output value of the thermal transducer TT-01-1 may be mapped to Profibus
DP service access point 47,001. Similarly, the output status of a pressure transducer
pp-44-1 of device 3051-44 on segment 3 may be mapped to Profibus DP service
access point 45,324, while the output value of the pressure transducer PP-44-1 may be
mapped to service access point 47,647. Once the Fieldbus process control parameters
are mapped to the Profibus DP service access points, the master devices in the
Profibus DP network 12 may request the current values of Fieldbus process control
parameters from the interface module 16 using the corresponding service access point
122 in the manner described more fully herein.
(0044] While the service access point database 100 illustrated herein maps
output values and output statuses of the function blocks to Profibus DP service access
points, it will be apparent to those skilled in the art that any process control
parameters used by the Fieldbus devices of a Fieldbus process control network may
be mapped to Profibus DP service access points in a service access point database. It
will be appreciated that the Fieldbus process control parameters mapped to the
Profibus DP service access points may be determined by the requirements of process
control system in which the interface module 16 is implemented. Moreover,
parameters of the Fieldbus process control network 14 may be mapped to
corresponding date structures for process control networks 12,17 connected to the I/O
modules 94, 104. Also, the interface module 16 may map process control parameters
for the process control networks 12, 17 to Fieldbus process control parameters, or
parameters for non-Fieldbus process control networks may be mapped to parameters
for other non-Fieldbus process control networks connected to the interface module 16,
in order to facilitate the exchange of information as necessary to integrate the process
control networks connected by the interface module 16.
[0045J Returning to the Profibus DP example, in order to establish the
service access point database 120, the interface module 16 must first identify the
function blocks and process control parameters existing in the field devices 36-66 of
the Fieldbus network 14. As previously discussed, once the interface module 16 is
connected to one or more of the segments 68a, 68b, G8c and 68d of the Fieldbus
network 14 via the Fieldbus I/O modules 96-102, the link active schedules of the
corresponding LAS field devices 36, 48, 56 and 64 are configured to transmit pass
token messages for the interface module 16 during the asynchronous period of the
schedule. When the interface module 16 receives a pass token message on one of the
segments 68a, 68b, 68c or 68d, the interface module 16 transmits messages on the
segment to poll the corresponding field devices for information relating to their
existence, the function blocks contained therein, and the process control parameters
used by the function blocks. For example, when the interface module 16 is connected
to segment 68a, and LAS field device 36 transmits a pass token message to the
Fieldbus address of the interface module 16, the Fieldbus I/O module 96 detects the
past token message and communicates to the controller 90 that the interface module
16 may transmit messages on segment 68a. The controller 90 causes the Fieldbus I/O
module 96 to transmit messages on the segment 68a polling the field devices 36-42
for information pertaining to the function blocks and process control parameters
contained therein. The field devices 36-42 respond by transmitting messages to the
interface module 16 containing the requested information. The response messages are
detected by the Fieldbus I/O module 96, which relays the information to the controller
90. The processor 106 of the controller 90 causes the information from the field
devices 36-42 to be stored in memory 108 for use in constructing the service access
point database 120. Similar polling'of the field devices 44-66 of the segment 68b, 6Sc
and 68d, if any, to which the interface module 16 is attached will be performed by the
controller 90.
[0046] Once information relating to the process control parameters of the
Fieldbus network 14 has been compiled by the interface module 16, the process
control parameters may be mapped to Profibus DP service access points using the
web browser of the user interface 86. Information for the available process control
parameters stored in the memory 108 may be transmitted from the controller 80
through the Internet I/O module 104 to the to user interface 86 upon receiving a
service request from the user interface 86. Once displayed, the web pages provided
by the web server software of the controller 90 allow the user to view the available
process control parameters and to map the process control parameters to Profibus DP
service access points for use by the Profibus DP network 12. As service access points
are assigned to the process control parameters, the information may be transmitted
from the user interface 86 to the interface module 16 and, after the information is
received at the Internet I/O module 104, the processor 106 of the controller 90 may
cause the service access points to be stored in the service access point database 120 in
entries corresponding to the associated process control parameters.
[0047] In an alternative embodiment, the Fieldbus process control
parameters may be mapped to the Profibus DP service access points at the user
interface 86 using software other than a web browser. The mapping may be
performed using commercially available software applications such as, for example,
the Microsoft® Excel spreadsheet program, or custom developed software
applications. The software application may issue a request for information for the
available process control parameters stored in the memory 108 via the Ethernet
connection between the user interface 86 and the interface module 16. The processor
106 of the controller 90 may respond by retrieving the requested information stored in
the memory 108 and causing the Internet I/O module 104 to transmit the retrieved
information to the user interface 86 via the Internet connection. Once the information
is received by the user interface 86 and displayed by the software application, the
software application allows the user to view the information relating to the available
process control parameters, and to manipulate the information to map the process
control parameters to Profibus DP service access points for use by the Profibus DP
network 12. As service access points are assigned to the process control parameters
using the software application, the updated information may be transmitted from the
user interface 86 to the interface module 16 and, after the information is received at
the Internet I/O module 104, the processor 106 of the controller 90 may cause the
service access points to be stored in the service access point database 120 in entries
corresponding to the associated process control parameters.
[0048J In addition to an operator manually mapping the Profibus DP service
access points to the Fieldbus process control parameters using the web browser at the
user interface 86, the interface module 16 may include an automatic mapping mode
whereby the controller 90 of the interface module 16 automatically assigns service
access points to the process control variables at the field devices 36-66. The
automatic mapping may assign service access points randomly or sequentially without
regard to the type of parameter being mapped or, alternatively, pre-determined ranges
of service access points may be designated for various types of parameters that may
be used in the Fieldbus network 14.
[0049) Once the process control parameters of the Fieldbus network 14 are
mapped to the service access points of the Profibus DP network 12, th« host 18 and
other master devices are configured to issue service requests to the interface module
16 for the values of Profibus DP service access points to which the process control
parameters of the Fieldbus network 14 have been mapped. The configuration of the
Profibus DP devices may be performed manually by an operator at a particular
Profibus DP master device. Alternatively, the configuration process may be -semiautomated
by having the processor 106 of the controller 90 cause the non-Internet I/O
module 94 to transmit messages to the master devices,of the Profibus DP network 12
that contain the service access points that have been mapped to Fieldbus process
control parameters. The data contained in these messages may be used by the
operator to configure the Profibus DP master devices to issue service -request
messages to the interface module 16 to retrieve the values associated with the mapped
service access points.
[0050] The service request messages issued by the Profibus DP master
devices include the Profibus DP device address for the interface module 16, a service
code requesting the interface module 16 to read the value of a service access point or
service access points, and the service access point or numbers to be read by the
interface module 16. The request messages are received at the non-Internet I/O
module 94, which decodes the request message and communicates the requests to the
controller 90. Upon receiving the request, the processor 106 of the controller 90 reads
the service access point database 120 stored in the memory 108 to retrieve the values
of the process control parameters corresponding to the service access point or
numbers requested by the Profibus DP master devices. Once the value or values have
been retrieved, the processor 106 causes the non-Internet I/O module 94 to format and
transmit a Profibus DP response message or messages containing the values stored in
the service access point database 120 to the requesting master device or devices.
[0051] In order to insure that the service access point database 120 includes
current values of the Fieldbus process control parameters stored therein, the processor
106 of the controller 90 may cause the Fieldbus I/O modules 96-102 to transmit
Fieldbus request messages to the field devices 36-66. Upon receiving pass token
messages on the corresponding segment 68a, 68b, 68c and 68d, the Fieldbus I/O
modules 96-102 may transmit messages to each of the field devices 36-66 for which
at least one process control parameter has been mapped to a Profibus DP service
access point. These messages may be transmitted each time a pass token message is
received, or may be transmitted less frequently depending on the type of process
control parameter or field device, or on the message transmission volume limitations
of the Fieldbus network 14. Alternatively, upon receiving a request from a Profibus
DP master device for the current value of a Profibus DP service access point, the
controller 90 may be configured to cause the corresponding one of the Fieldbus I/O
modules 96-102 to transmit a request to the appropriate one of the field devices 36-66
for the current value of the process control parameter. Once the one of the field
devices 36-66 responds with the requested process control parameter value, the
processor 106 may update the service access point database 120 with the new value
and cause the non-Internet I/O module 94 to transmit the appropriate response
message to the requesting Profibus DP master device.
[0052J As previously stated, the illustrated Fieldbus-to-Profibus DP
mapping is exemplary only. The interface module 16 may further be configured to
map service access points of the Profibus DP network 12 to Fieldbus parameters of
the Fieldbus network 14 such that the interface module 16 may store values of the
service access points from the Profibus DP devices and transmit those values in
response to requests from the Fieldbus devices. As another example, a ModBus TCP
network may be connected to the interface module 16 at the Internet I/O module 104,
with parameters of the Fieldbus network mapped to ModBus TCP data structures and
vice versa and, if desired, data structures of the ModBus TCP network mapped to data
structures of a non-Internet network connected to the non-Internet I/O module 94 or
another Internet-based network connected to the internet I/O module 104. Still
further, the interface module 16 may be configured with additional I/O modules 84-
104 to facilitate connection and integration of a desired number of process control
networks 12,14,17.
[0053] In order to ensure a substantially constant connection between the
process control networks connected by the interface module 16, the interface module
16 and the connection provided thereby may be configured with redundant systems in
addition to any redundancy mechanisms implemented in within the connected process
control networks. In one embodiment, multiple interface modules 16 may be
connected between two or more process control networks in the same -configuration
such that each interface module 16 may be -capable of receiving messages and
responding on the process control networks. Moreover, the interface modules 16 may
be connected to the user interface 86 such that each of the interface modules 16 may
be configured by the user interface 86 in the manner discussed above. The user
interface 86 may be configured to configure each of the interface modules 16 so that
each of the interface modules 16 is prepared to operate to communicate information
between the process control networks. In operation, one of the interface modules 16
may be active at a given time to respond to requests from the field devices of the
process control networks, while the remaining interface modules) 16 may be ^et to a
standby mode wherein the interface module(s) 16 receive information from the field
devices and update the information stored in the database(s) in order to remain
synchronized with the active interface module 16. Mode control for the interface
modules 16 may be effected via a connection between the interface modules 16, via
the user interface 86, or via another common connection between interface modules
16 such that the status of the interface modules 16 may be monitored, and the
operational mode of the interface modules 16 as active or standby may be adjusted,
either manually or automatically based on changes in the status of the interface
modules 16 so that an active connection may be maintained between the connected
process control networks.
[0054] As a further alternative, redundancy may be built into the interface
modules 16 themselves by providing either multiple I/O modules 94, 104, or multiple
input ports for the I/O modules 94, 104 so that a constant connection of the interface
module 16 to a given process control network may be maintained. Fig. 4 illustrates an
embodiment of the interface module 16 wherein a second Internet I/O module 140 is
provided, at least in part, to provide redundancy within the interface module 16. The
Internet I/O module 140 may be similar to the Internet I/O module 104, and may be
connected to the controller 90 and include a communications port or wireless
communications capability for connecting the Internet I/O module 140 to the Internetbased
process control network 17 and/or the user interface 86. In the illustrated
embodiment, the Internet I/O modules 104, 140 may be connected to the Internetbased
process control network 17 to facilitate communications between the interface
module 16 and the process control network 17 and user interface 86. At a given time,
one of the Internet I/O modules 104, 140 may be designated by the controller 90 as
the active module for communications with the Internet process control network 17
and the user interface 86, while the other of the Internet I/O modules 104,140 may be
designated by the controller 90 as the standby module that is available in the event
communications through the active module are disrupted, such as in the event of a
software failure or loss of connection to the process control network 17. The
controller 90 may be configured to detect such communication disruptions and to
place the standby module into active status for communications with the process
control network 17, and to disable the active module from service so that the
communication disruption may be remedied. Additionally, the controller 90 may
transmit a message regarding the status of the disabled I/O module 104, 140 to an
appropriate device in one of the connected process control networks 12, 14, 17 for
notifying a system operator of the condition of the interface module 16. While the
redundancy illustrated and described herein relates to the Internet I/O modules 104,
140, those skilled in the art will understand that similar redundancy strategies may be
implemented with any of the I/O modules of the interface module 16 to ensure
constant communication links with any process control networks 12,14,17 connected
thereto.
[0055] While the preceding text sets forth a detailed description of
numerous different embodiments of the invention, it should be understood that the
legal scope of the invention is defined by the words of the claims set forth at the end
of this patent. The detailed description is to be construed as exemplary only and does
not describe every possible embodiment of the invention since describing every
possible embodiment would be impractical, if not impossible. Numerous alternative
embodiments could be implemented, using either current technology or technology
developed after the filing date of this patent, which would still fall within the scope of
the claims defining the invention.


CLAIMS
What is claimed is:
1. An interface module for use in a process control system including a
Fieldbus process control network having a plurality of Fieldbus field devices and a
Profibus DP process control network having a plurality of Profibus DP field devices,
the interface module operatively connecting the Fieldbus process control network to
the Profibus DP process control network and being adapted to facilitate the exchange
of process control information between the Fieldbus process control network and the
Profibus DP process control network, the interface module comprising:
a Fieldbus I/O module operarively connected to the Fieldbus process control
network and being adapted to transmit and receive Fieldbus protocol messages on the
Fieldbus process control network;
a Profibus DP I/O module operatively connected to the Profibus DP process
control network and being adapted to transmit and receive Profibus DP protocol
messages on the Profibus DP process control network; and
a controller operatively connected to the Fieldbus I/O module and the Profibus
DP I/O module, the controller comprising a processor and a memory operatively
connected to the processor,
the controller being programmed to store in the memory a service
access point database wherein at least one Fieldbus process control parameter
of the Fieldbus process control network is associated with a Profibus DP
service access point of the Profibus DP process control network,
the controller being programmed to cause the Fieldbus I/O module to
request a current value of the at least one Fieldbus process control parameter
from a corresponding one of the Fieldbus field devices,
the controller being programmed to store the current value of the at
least one Fieldbus process control parameter in the service access point
database with the associated Profibus DP service access point, and
the controller being programmed to cause the Profibus DP I/O module to
transmit a response message to one of the Profibus DP field devices with the current
value of the at least one Fieldbus process control parameter and the associated
Profibus DP service access point in response to receiving a request message from the
one of the Profibus DP field devices at the Profibus DP I/O module for the current
value of the associated Profibus DP service access point.
2. The interface module of claim 1, wherein the controller is programmed
to cause the Fieldbus I/O module to request the current value of the at least one
Fieldbus process control parameter from the corresponding one of the Fieldbus field
devices using queued, unscheduled communications on each occurrence of receiving
a pass token message at the Fieldbus I/O module from the Fieldbus process control
network.
3. The interface module of claim 1, wherein the controller is programmed
to cause the Fieldbus I/O module to request the current value of the at least one
Fieldbus process control parameter from the corresponding one of the Fieldbus field
devices after a predetermined period of time elapses after the Fieldbus I/O module
issued a previous request for the current value of the at least one Fieldbus process
control parameter.
4. The interface module of claim 1, wherein the controller is programmed
to cause the Fieldbus I/O module to request the current value of the at least one
Fieldbus process control parameter from the corresponding one of the Fieldbus field
devices in response to receiving the request message from the one of the Profibus DP
field devices at the Profibus DP I/O module for the current value of the associated
Profibus DP service access point.
5. The interface module of claim 1, wherein the Fieldbus process control
network includes a plurality of segments each having at least one Fieldbus field
device operatively connected thereto, the interface module comprising a plurality of
Fieldbus I/O modules each being operatively connected to the controller and one of
the segments of the Fieldbus process control network, each Fieldbus I/O module
being adapted to transmit and receive Fieldbus protocol messages on the
corresponding one of the segments, the controller being programmed to cause the one
of the Fieldbus I/O modules operatively connected to the one of the segments to
which the corresponding one of the Fieldbus field devices is operatively connected to
request a current value of the at least one Fieldbus process control parameter.
6. The interface module of claim 1, comprising an Ethernet I/O module
operatively connected to the controller and to a user interface, and being adapted to
transmit Ethernet protocol messages to and receive Ethernet protocol messages from
the user interface.
7. The interface module of claim 6, wherein the user interface is
programmed to function as a web browser and the controller is programmed to
function as a web server.
8. The interface module of claim 6, wherein the controller is programmed
to cause the Ethernet I/O module to transmit information relating to the at least one
Fieldbus process control parameter to the user interface in response to receiving a
request message from the user interface at the Ethernet I/O module.
9. The interface module of claim 6, wherein the -controller is programmed
to update the service access point database in the memory to associate the at least one
Fieldbus process control parameter of the Fieldbus process control network with the
Profibus DP service access point of the Profibus DP process control network in
response to receiving a service access point database update message from the user
interface at the Ethernet I/O module.
10. The interface module of claim 6, wherein the controller is programmed
to cause the Ethernet I/O module to transmit a response message to the user interface
with the current value of the at least one Fieldbus process control parameter,
information relating to the at least one Fieldbus process control parameter, and the
associated Profibus DP service access point in response to receiving a request
message from the user interface at the Ethernet I/O module for the -service access
point database.
11. A process control system comprising:
a Fieldbus. process control network having a plurality of Fieldbus field
devices;
a Profibus DP process control network having a plurality of Profibus DP field
devices; and
an interface module operatively connecting the Fieldbus process control
network to the Profibus DP process control network and being adapted to facilitate the
exchange of process control information between the Fieldbus process control
network and the Profibus DP process control network, the interface module
comprising:
a Fieldbus I/O module operatively connected to the Fieldbus process
control network and being adapted to transmit and receive Fieldbus protocol
messages on the Fieldbus process control network,
a Profibus DP I/O module operatively connected to the Profibus DP
process control network and being adapted to transmit and receive Profibus
DP protocol messages on the Profibus DP process control network, and
a controller operatively connected to the Fieldbus I/O module and the
Profibus DP I/O module, the controller comprising a processor and a memory
operatively connected to the processor,
the controller being programmed to store in the memory a
service access point database wherein at least one Fieldbus process
control parameter of the Fieldbus process control network is associated
with a Profibus DP service access point of the Profibus DP process
control network,
the controller being programmed to cause the Fieldbus I/O
module to request a current value of the at least one Fieldbus process
control parameter from a corresponding one of the Fieldbus field
devices,
the controller being programmed to store the current value of
the at least one Fieldbus process control parameter in the service
access point database with the associated Profibus DP service access
point, and
the controller being programmed to cause the Profibus DP I/O module to
transmit a response message to one of the Profibus DP field devices with the current
value of the at least one Fieldbus process control parameter and the associated
Profibus DP service access point in response to receiving a request message from the
one of the Profibus DP field devices at the Profibus DP I/O module for the current
value of the associated Profibus DP service access point.
12. The process control system of claim 11, wherein the controller of the
interface module is programmed to cause the Fieldbus I/O module to request the
current value of the at least one Fieldbus process control parameter from the
corresponding one of the Fieldbus field devices using queued, unscheduled
communications on each occurrence of receiving a pass token message at the Fieldbus
I/O module from the Fieldbus process control network.
13. The process control system of claim 11, wherein the controller of the
interface module is programmed to cause the Fieldbus I/O module to request the
current value of the at least one Fieldbus process control parameter from the
corresponding one of the Fieldbus field devices after a predetermined period of time
elapses after the Fieldbus I/O module issued a previous request for the-current value
of the at least one Fieldbus process control parameter.
14. The process control system of claim 11, wherein the controller of the
interface module is programmed to cause the Fieldbus I/O module to request the
current value of the at least one Fieldbus process control parameter from the
corresponding one of the Fieldbus field devices in response to receiving the request
message from the one of the Profibus DP field devices at the Profibus DP I/O module
for the current value of the associated Profibus DP service access point.
15. The process control system of claim 11, wherein the Fieldbus process
control network includes a plurality of segments each having at least one Fieldbus
field device operatively connected thereto, and wherein the interface module
comprises a plurality of Fieldbus I/O modules each being operatively-connected to the
controller and one of the segments of the Fieldbus process -control network, each
Fieldbus I/O module being adapted to transmit and receive Fieldbus protocol
messages on the corresponding one of the segments, the controller being programmed
to cause the one of the Fieldbus I/O modules operatively connected to the one of the
segments to which the corresponding one of the Fieldbus field devices is operatively
connected to request a current value of the at least one Fieldbus process control
parameter.
16. The process control system of claim 11, wherein the interface module
comprises an Ethernet I/O module operatively connected to the controller, the process
control system comprising a user interface operatively connected to the Ethernet I/O
module, the Ethernet I/O module being adapted to transmit Ethernet protocol
messages to and receive Ethernet protocol messages from the user interface.
17. The process control system of claim 16, wherein the user interface is
programmed to function as a web browser and the controller is programmed to
function as a web server.
18. The process control system of claim 16, wherein the controller is
programmed to cause the Ethernet I/O module to transmit information relating to the
at least one Fieldbus process control parameter to the user interface in response to
receiving a request message from the user interface at the Ethernet I/O module.
19. The process control system of claim 16, wherein the controller is
programmed to update the service access point database in the memory to associate
the at least one Fieldbus process control parameter of the Fieldbus process control
network with the Profibus DP service access point of the Profibus DP process control
network in response to receiving a service access point database update message from
the user interface at the Ethernet I/O module.
20. The process control system of claim 16, wherein the controller is
programmed to cause the Ethernet I/O module to transmit a response message to the
user interface with the current value of the at least one Fieldbus process control
parameter, information relating to the at least one Fieldbus process control parameter,
and the associated Proflbus DP service access point in response to receiving a request
message from the user interface at the Ethernet I/O module for the service access
point database.
21. A method of exchanging process control information between a
Fieldbus process control network having a plurality of Fieldbus field devices and a
Profibus DP process control network having a plurality of Profibus DP field devices,
the method including the steps of:
operatively coupling an interface module to the Fieldbus process control
network and to the Profibus DP process control network, the interface module being
adapted to transmit and receive Fieldbus protocol messages on the Fieldbus process
control network and to transmit and receive Profibus DP protocol messages on the
Profibus DP process control network;
storing in the interface module a service access point database wherein at least
one Fieldbus process control parameter of the Fieldbus process control network is
associated with a Profibus DP service access point of the Profibus DP process control
network,
causing the interface module to request a current value of the at least one
Fieldbus process control parameter from a corresponding one of the Fieldbus field
devices,
storing the current value of the at least one Fieldbus process control parameter
in the service access point database with the associated Profibus DP service access
point, and
causing the interface module to transmit a response message to one of the
Profibus DP field devices with the current value of the at least one Fieldbus process
control parameter and the associated Profibus DP service access point in response to
receiving a request message from the one of the Profibus DP field devices at the
interface module for the current value of the associated Profibus DP service access
point.
22. The method of claim 21, further including the step of causing the
interface module to request the current value of the at least one Fieldbus process
control parameter from the corresponding one of the Fieldbus field devices using
queued, unscheduled communications on each occurrence of receiving a pass token
message at the interface module from the Fieldbus process control network.
23. The method of claim 21, further including the step of causing the
interface module to request the current value of the at least one Fieldbus process
control parameter from the corresponding one of the Fieldbus field devices after a
predetermined period of time elapses after the interface module issued a previous
request for the current value of the at least one Fieldbus process control parameter.
24. The method of claim 21, further including the step of-causing the
interface module to request the current value of the at least one Fieldbus process
control parameter from the corresponding one of the Fieldbus field devices in
response to receiving the request message from the one of the Profibus DP field
devices at the interface module for the current value of the associated Profibus DP
service access point.
25. The method of claim 21, wherein the Fieldbus process control network
includes a plurality of segments each having at least one Fieldbus field device
operatively connected thereto, the method further including the steps of:
operatively coupling the interface module to the segments of the Fieldbus
process control network; and
causing the interface module to transmit a request for a current value of the at
least one Fieldbus process control parameter on the one of the segments to which a
corresponding one of the Fieldbus field devices is operatively connected.
26. The method of claim 21, further comprising the step of operatively
coupling the interface module to a user interface, the interface module being adapted
to transmit Ethernet protocol messages to and receive Ethernet protocol messages
from the user interface.
27. The method of claim 26, wherein the user interface is programmed to
function as a web browser and the interface module is programmed to function as a
web server.
28. The method of claim 26, further including the step of causing the
interface module to transmit information relating to the at least one Fieldbus process
control parameter to the user interface in response to receiving a request message
from the user interface at the interface module.
29. The method of claim 26, further including the step of updating the
service access point database in the memory to associate the at least one Fieldbus
process control parameter of the Fieldbus process control network with the Profibus
DP service access point of the Profibus DP process control network in response to
receiving a service access point database update message from the user interface at
the interface module.
30. The method of claim 26, further including the step of causing the
interface module to transmit a response message to the user interface with the current
value of the at least one Fieldbus process control parameter, information relating to
the at least one Fieldbus process control parameter, and the associated Profibus DP
service access point in response to receiving a request message from the user interface
at the interface module for the service access point database.
31. The method of claim 26, wherein the interface module is adapted to
transmit Ethernet protocol messages to and receive Ethernet protocol messages from
the user interface.
32. An interface module for use in a process control system including a
Fieldbus process control network having a plurality of Fieldbus field devices and at
least one non-Fieldbus process control network having a plurality of non-Fieldbus
field devices, the interface module operatively connecting the Fieldbus process
control network to the non-Fieldbus process control network and being adapted to
facilitate the exchange of process control information between the Fieldbus process
control network and the at least one non-Fieldbus process control network, the
interface module comprising:
a Fieldbus I/O module operatively connected to the Fieldbus process control
network and being adapted to transmit and receive Fieldbus protocol messages on the
Fieldbus process control network;
a plurality of non-Fieldbus I/O modules each configured to operatively
connect to a non-Fieldbus process control network and to transmit and receive
messages communicated using a protocol other than the Fieldbus protocol on the
corresponding non-Fieldbus process control network; and
a controller operatively connected to the Fieldbus I/O module and the at least
one non-Fieldbus I/O module, the controller comprising a processor and a memory
operatively connected to the processor,
the controller being programmed to store in the memory a database
wherein at least one Fieldbus process control parameter of the Fieldbus
process control network is associated with a process control parameter of a
non-Fieldbus process control network, and wherein a value of the at Jeast one
Fieldbus process control parameter is stored in the database with an identifier
for the corresponding Fieldbus process control parameter and an identifier for
the corresponding process control parameter of the non-Fieldbus process
control network,
the controller being programmed to cause the Fieldbus I/O module to
request a current value of the at least one Fieldbus process control parameter
from a corresponding one of the Fieldbus field devices,
the controller being programmed to store the current value of the at
least one Fieldbus process control parameter in the database with the identifier
for the corresponding process control parameter of the non-Fieldbus process
control network, and
the controller being programmed to cause one of the non-Fieldbus I/O
modules to transmit a response message to one of the non-Fieldbus field
devices of the corresponding non-Fieldbus process control network with the
current value of the at least one Fieldbus process control parameter stored in
the database and the identifier for the corresponding non-Fieldbus process
control parameter in response to receiving a request message from the one of
the non-Fieldbus field devices at the non-Fieldbus I/O module for the current
value of the non-Fieldbus process control parameter.
33. The interface module of claim 32, wherein at least one of the non-
Fieldbus I/O modules is an Internet-compatible I/O module and the field devices of
the corresponding non-Fieldbus process control network operatively connected
thereto perform process control using an Internet-based communication protocol.
34. The interface module of claim 33, wherein the controller is
programmed to communicate with a user interface operatively connected to the
Internet-compatible I/O module and to cause the Internet-compatible I/O module to
transmit messages to and receive messages from the user interface.
35. The interface module of claim 32, comprising two non-Fieldbus I/O
modules operatively connected to the same non-Fieldbus process control network, the
controller being programmed to cause both non-Fieldbus I/O modules to transmit
messages to and receive messages from the non-Fieldbus field devices on the non-
Fieldbus process control network.
36. The interface module of claim 32, wherein the process control system
includes two non-Fieldbus process control networks each having a plurality of non-
Fieldbus field devices, wherein a first of the non-Fieldbus I/O modules is operatively
connected to the first non-Fieldbus process control network and a second of the non-
Fieldbus I/O modules is operatively connected to the second non-Fieldbus process
control network, the controller being programmed to cause the first non-Fieldbus I/O
module to transmit messages to and receive messages from the non-Fieldbus field
devices on the first non-Fieldbus process control network, and to cause the -second
non-Fieldbus I/O module to transmit messages to and receive messages from the non-
Fieldbus field devices on the second non-Fieldbus process control network.
37. The interface module of claim 36, wherein the non-Fieldbus field
devices of the first non-Fieldbus process control network communicate using a first
communication protocol and the non-Fieldbus field devices of the second non-
Fieldbus process control network communicate using a second communication
protocol, and wherein the first communication protocol is different from the second
communication protocol.
38. The interface module of claim 37, wherein the first communication
protocol is an Internet-based communication protocol and the second communication
protocol is a non-Internet based communication protocol.
39. A method of exchanging process control information between a
Fieidbus process control network having a plurality of Fieldbus field devices and a
plurality of non-Fieldbus process control networks each having a plurality of non-
Fieldbus field devices, the method including the steps of:
operatively connecting an interface module to the Fieldbus process control
network and to the non-Fieldbus process control networks, the interface module being
configured to transmit and receive Fieldbus protocol messages on the Fieldbus
process control network and to transmit and receive non-Fieldbus protocol messages
on the non-Fieldbus process control networks;
storing in the interface module a database wherein at least one process control
parameter of the Fieldbus process control network is associated with a process control
parameter of one of the non-Fieldbus process control networks, and wherein a value
of the at least one process control parameter is stored in the database with an identifier
for the corresponding process control parameter of the Fieldbus process control
network and an identified for the corresponding process control parameter of the non-
Fieldbus process control network,
causing the interface module to request a current value of the at least one
process control parameter from a corresponding one of the field devices in the
Fieldbus process control network,
storing the current value of the at least one process control parameter of the
Fieldbus process control network in the database with the identifier for the
corresponding process control parameter of the non-Fieldbus process control network,
and
causing the interface module to transmit a response message to one of the field
devices of the non-Fieldbus process control network with the current value of the at
least one process control parameter of the Fieldbus process control network and the
identifier for the corresponding process control parameter of the non-Fieldbus process
control network in response to receiving a request message from the one of the field
devices of the non-Fieldbus process control network at the interface module for the
current value of the process control parameter of the non-Fieldbus process control
network.
40. The method of claim 39, further comprising providing a second
operative connection of the interface module to one of the non-'Fieldbus process
control networks, the interface module being configured to transmit and receive non-
Fieldbus protocol messages on the non-Fieldbus process control network via the
second operative connection.
41. The method of claim 39, wherein the non-Fieldbus field devices of a
first of the non-Fieldbus process control networks communicate using a first
communication protocol and the non-Fieldbus field devices of the second of the non-
Fieldbus process control networks communicate using a second communication
protocol, and wherein the first communication protocol is different from the second
communication protocol.
42. The method of claim 41, wherein the first communication protocol is
an Internet-based communication protocol and the second communication protocol is
a non-Internet based communication protocol.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=tBf3qVGTshBnLPMKQwg0PQ==&loc=+mN2fYxnTC4l0fUd8W4CAA==


Patent Number 269668
Indian Patent Application Number 1170/DELNP/2007
PG Journal Number 45/2015
Publication Date 06-Nov-2015
Grant Date 30-Oct-2015
Date of Filing 13-Feb-2007
Name of Patentee ROSEMOUNT, INC.
Applicant Address 12001 TECHNOLOGY DRIVE, EDEN PRAIRIE, MN 55344-3695, USA
Inventors:
# Inventor's Name Inventor's Address
1 ROBERT J.KARSCHNIA 253 JASPERS CIRCLE NORTH, CHASKA, MN 55318, USA
2 ERIC D. ROTVOLD 8450 ANN MARIE TRAIL, INVER GROVE HEIGHTS, MN 55077,USA
3 ROBERT TRAIN 5 FRIARY CLOSE, MIDDLETON ON SEA, BOGNOR RGIS, WEST SUSSEX PO22 6PB,ENGLAND
4 MARCOS A. V.PELUSO 8301 WEST LAKE COURT, CHANHASSEN, MN 55317, USA
PCT International Classification Number G05B 19/418
PCT International Application Number PCT/US2005/030765
PCT International Filing date 2005-08-30
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/931,165 2004-08-31 U.S.A.