Patent Application
20250004436
The instant application claims priority to European Patent Application No. 23182359.2, filed Jun. 29, 2023, which is incorporated herein in its entirety by reference.
The present disclosure generally relates to a process control system and, more particularly, to an input/output-system.
Process control systems are generally known in the prior art. Process control systems may comprise several different hardware units. Process control systems may be used to control complex production plants, e.g. in process industry or automobile industry. In practice, a process control system comprises several different field devices, which are connected with the I/O modules on the module termination unit. I/O signals of a process control system are collected and distributed by remote I/O systems typically installed very close to the automation process. These remote I/O-systems are connected to the process control systems via fieldbuses. The conversion of fieldbus signals into data objects that are suited for reading, processing and understanding by the controller will be made in a unit which is called fieldbus communication interface (FCI) or sometimes called communication interface (CI).
Control equipment for process automation needs to be available as product and service spare parts for very long time, but the electronic market changes much faster. In case that hardware components must be updated then multiply variants of fieldbus communication interface Hardware for each fieldbus type must be redesigned which leads to a huge maintenance effort.
It has now become apparent, due to the above reasons, that there is a need to provide a further process control system.
According to an aspect of the present disclosure, a process control system is provided comprising: at least one module termination unit; at least one adapter module arranged on the module termination unit and configured to communicate with a field device; and at least one controller module arranged on the module termination unit and configured to process signals from the adapter module; wherein the adapter module and the controller module are connected to each other by a peer-to-peer connection, in particular through the module termination unit.
The module termination unit may also be described as a mounting termination unit. The module termination unit may also be described as a baseplate or a backplane. The module termination unit is configured to hold the adapter module and the control module. Further modules may be arranged at the module termination unit, for example a power module. The module termination unit may comprise electric circuits for powering the modules and for data transfer between the modules.
The adapter module may contain/comprise, preferably only, the fieldbus specific transceivers and/or hardware-drivers. The adapter module may be connected to an input/output module or I/O module, in particular a remote I/O module.
The adapter module and the control module are connected by a peer-to-peer connection. The peer-to-peer connection is provided through the module termination unit. The peer-to-peer connection may also be described as peer-to-peer adapter channel. The peer-to-peer connection may comprise any possible type of signal. The signal type of the peer-to-peer connection may be an electrical single ended signal, an electrical differential signal, a wireless signal or an optical signal. Signals from an I/O-device go through the adapter module via the peer-to-peer connection to the controller module. The signals may also be described as field device data, since the data which is transferred through the peer-to-peer connection may originate from a field device.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention.
A modern process control system may comprise many different elements and each embodiment shown in the Figures comprises only those elements that are relevant/necessary for that embodiment.
The adapter modules 12 comprise transceiver elements 19. The transceiver elements 19 may comprise fieldbus specific transceivers and/or hardware-driver. This may also be described as first hardware layer hardware.
The controller module 13 comprises two fieldbus communication processors 20. The fieldbus communication processors 20 in the controller module 13 preferably handle all specifics of a fieldbus protocol. The controller module 13 further comprises an execution element 22 or process automation execution engine. The fieldbus communication processor 20 may be used for the execution element 22 and for one ore multiply instances of same or different fieldbus types. The term execution element may be understood broadly. The execution element 22 may also be used to collect and distribute fieldbus/process data to other components of process control system 10 (Connectivity element).
The controller module 13 is connected to the adapter module 12 by separate peer-to-peer connections 14. More precisely the two fieldbus communication processors 20 are each connected to the transceiver elements 19 of the adapter modules 12 by a peer-to-peer connection 14. The peer-to-peer connections 14 are preferably arranged at least partially in the module termination unit 11.
The peer-to-peer connections 14 may also be described as peer-to-peer adapter channel. The peer-to-peer connections 14 may not be limited to one signal. Rather a set of signals are combined in one peer-to-peer connection 14.
An example for a fieldbus may comprise controlling a RS485 transceiver/driver for PROFIBUS DP. In this case, three signals would be needed for transmit, receive and direction control. Another example for a fieldbus may comprise controlling a Modulebus device such as devices manufactured by ABB. For this, five signals would be needed. One signal each for transmit, receive, direction control, synchronization clock and synchronization clock enable.
The adapter modules 12 further comprise each a configuration unit 16, and the controller module 13 contains a configuration unit manager 17. The configuration units and configuration unit manager 17 are designed to communicate via a service Bus connection 18 which may be arranged on the module termination unit 11.
Preferably, the configuration unit manager 17 may act as a client on the service Bus connection 18 and the configuration unit 16 as a server. The configuration unit manager 17 may know the desired settings of the selector elements 15. This knowledge about aimed settings can be specified from the engineering tool or can be determined from the existing modules in the module termination unit 11. The configuration unit manager 17 controls the selector elements 15 in the controller module 13 and sends the target settings to the respective configuration unit 16 in the adapter modules 12. The configuration unit 16 in the adapter modules 12 controls the selector elements 15 according the target settings. In other words the selector element 15 switches to a desired peer-to-peer connection 14 according to the target settings.
The configuration unit 16 and selector element 15 adapter module may be realized for example by a programmable logic, for example a field programmable gate array (FPGA) circuit. The signals of the peer-to-peer connection 14 may be digital signals, this means that the selector element 15 can be realized as logic gates. The service Bus connection 18 may be realized for example by an I2C Bus, related FPGA-IP-Cores are also possible. The size and complexity of such kind of selector elements 15 and configuration units 16 can be realized in a small size. One important feature of the selector elements 15 and configuration units 16 is that no fieldbus specific protocol knowledge needs to be implemented in the adapter module 12.
This allows flexible usage of Adapter Slots and assignment to Controllers with spare resources. Especially in case of extensions and changes of the process control application this kind of flexibly is very helpful.
As a first option, the selector element 15 in the adapter module 12 switches immediately to peer-to-peer connection 14 of the backup controller module 13, if the primary controller module fails. Switching the selector element 15 in the adapter module may be performed in different ways.
According to one way, the configuration unit manager 17 of the backup controller module 13 sends the new configuration settings to the configuration Unit 17 of the adapter module 12.
According to another way, the selector element 15 in the adapter module 12 has an automatic function to switch to the backup controller module 13, after a specific pre-defined pattern of the auxiliary signals was detected. It is also possible that the backup controller module 13 receives and detects the signals in a passive way.
As a second option, the logic of the selector element 15 of the adapter module 12 emulates the BUS node functionality. This means that the logic in the selector element 15 behaves like he primary controller module and backup controller module 13 had its own transceiver element 19 on the same Bus. If one or both fieldbus communication processors 20 in the controller modules 13 don't behave correct according to bus rules, then it could lead to impermissible states. But this would also be the case if each controller module 13 had its own transceiver element 19 to the same fieldbus device. This kind of functionality of the selector element would also allow the backup controller module 13 to detect the communication between the primary controller module 13 and I/O-device (Remote I/O). By doing so the backup controller module 13 gets the same process image of the I/Os and could take over immediately in case the Primary fails.
Any disclosure and embodiments described herein relate to the process control system 10, lined out above or below and vice versa. The benefits provided by any of the embodiments and examples equally apply to all other embodiments and examples and vice versa.
Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from the study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps and the indefinite article “a” or “an” does not exclude a plurality. A single processor or other unit may fulfill the functions of several items or steps recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope of the claims.
The embodiments in accordance with the present disclosure allow high flexibility when selecting different fieldbus types. When a fieldbus is selected, it may be assigned freely to a controller module. Also, certain signals of the peer-to-peer connection can be used for fast detection of the insertion, the removal or the failure of a new or different adapter module. Furthermore, because of the peer-to-peer connection, no bandwidth limitation caused by the electric architecture may occur anymore, in particular compared to a bus architecture on the module termination unit. To achieve these features, a common generic CPU core may be used for all fieldbus types.
In an embodiment, the control module is connected to multiple adapter modules by peer-to-peer connections. This allows to control multiple field devices simultaneously. In particular multiple devices with same and/or different field bus protocols.
In an embodiment, the adapter module is connected to multiple controller modules by peer-to-peer connection. In that way, different settings may be possible. Also, one controller module may be used as a backup for redundancy reasons.
In an embodiment, at least one controller module of the multiple controller modules is a redundancy controller module. By doing this, possible stand stills may be prevented.
In an embodiment, the peer-to-peer connection comprises multiple peer-to-peer signal channels, in particular two-way channels and/or one-way channels. More precisely, a set of peer-to-peer wirings are combined to the peer-to-peer connection or peer-to-peer adapter channel with several differential and single ended signals. For some connections, several signal must be provided/possible. For example, to control a RS485 transceiver/driver for PROFIBUS DP, three signals are needed: transmit, receive and direction control. In a different example, to control ABB's modulebus, five signals are needed: transmit, receive, direction control, synchronization clock and synchronization clock enable.
In an embodiment, the adapter module comprises a selector element, the selector element being configured to select one of a plurality of peer-to-peer connections. This means, the selector element is configured to switch between different peer-to-peer connections. The selector element may be a software logic or a hardware element.
In an embodiment, the adapter module comprises a configuration element, the configuration element being configured to control the selector element. The configuration element may be connected to the control module, to control to which peer-to-peer connection the selector element should switch.
In an embodiment, the control module comprises a configuration unit, wherein the configuration unit is configured to communicate with the configuration element of the adapter module. The configuration unit is configured to control the configuration elements of the adapter modules. The configuration unit may also be described as configuration manager. The configuration unit communicates with the configuration elements.
In an embodiment, the selector element of the adapter module comprises a peer-to-peer connection to the selector element of the control module and the configuration element of the adapter module comprises a service BUS connection to the configuration unit of the control module. More precisely, the configuration element or multiple configuration elements and the configuration unit or multiple configuration units may be connected to each other by a single BUS connection. The single BUS connection may be a service BUS connection and/or a redundant configuration BUS connection. It is also possible, that there may be more than one BUS connection.
The module termination unit preferably comprises multiple peer-to-peer adapter channels. A flexible assignment of adapter modules to control modules may be established by the selector elements according to application demands. As mentioned above, the control module and adapter module each use a service BUS connection for setting the selector elements to a desired/chosen peer-to-peer connection.
In an embodiment, the adapter module and the controller module are separate hardware components. This allows to switch out or repair any module separately. Alternatively the adapter module hardware and control module hardware may be placed in the same module housing. Then, the adapter module may be connected directly with the controller module without a connection in the module termination unit.
In an embodiment, the peer-to-peer connection is achieved through a wiring in the module termination unit. More precisely, the wiring is embedded inside and/or on the module termination unit. For example the wiring may be embedded in a plate or the sort of the module termination unit.
In an embodiment, the wiring of the peer-to-peer connection in the module termination unit is a passive wiring. This means, the wiring may be used universally.
In an embodiment, the adapter module comprises transceiver elements for one or multiple fieldbuses. The transceiver elements may be used to transform the signals from the I/O-device such that the signals may be send through the peer-to-peer connection.
In an embodiment the control module comprises a fieldbus communication processor for one or multiple fieldbuses. The fieldbus communication processor may consist of hardware and software elements. The fieldbus communication processor may be configured to process the signals received by the peer-to-peer connection. The fieldbus communication processor may comprise a CPU core with Memory and may be used for process automation control. The term CPU core may be understood broadly in the context of the present invention. The term CPU core may comprise all typical characteristics of a modern digital processing system like a CPU, MCU, SoC, FPGA, DSP, and/or AI-Engine.
The fieldbus communication processor may have one ore multiple fieldbus communication processors instances of same or different Fieldbus types.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
| Number | Date | Country | Kind |
|---|---|---|---|
| 23182359.2 | Jun 2023 | EP | regional |
