Industrial process control and automation systems with decoupled controllers

Abstract

The present invention is entitled an industrial process control and automation system with a decoupled controller. A device for use in an industrial process control and automation system operating using an open platform data communication protocol is disclosed. The device includes: a processor and a memory; and a communication interface connected to at least one process device and arranged to transmit instructions to at least one process device and a data network of an industrial process control and automation system communicating using an open platform data communication protocol and receive data from at least one process device. The device memory contains: a system repository file containing process data information sent from at least one process device to the device; a stored function block definition file containing function blocks defining a control strategy for controlling at least one process device; and an engineering repository containing characteristics and parameters of function blocks associated with at least one process device. The processor operates to communicate process data from the system repository file to the industrial process control and automation system using the open platform data communication protocol, and receive instructions from the industrial process control and automation system to execute the control strategy.

Description

Technical Field

[0001] The present disclosure generally relates to industrial process control and automation systems. More specifically, the present disclosure relates to an industrial process control and automation system whose process controller is decoupled from its supervisory layer. Background Art

[0002] Industrial process control and automation systems are often used to automate large and complex industrial processes. These types of systems typically include various components, including sensors, actuators, and process controllers. The process controller receives measurements from the sensors and generates control signals for the actuators. Modern, mature (well-bred) process control systems are characterized by a set of well-integrated and unified operations from the system application layer to the control and sensing of various I / O devices. This control has been achieved in the following ways: a variety of networked devices such as servers are bundled to provide system applications (such as historical records and advanced control applications, workstations using various human-machine interfaces (HMI) solutions for operators of the control system) to switches, routers, firewalls, security systems, and proprietary real-time controllers as well as industrial field devices and other I / O elements. The integrated nature of such systems enables the coordinated behavior of all components, elements, and application layers of the system.

[0003] Many users of industrial process control and automation systems prefer one element, application or component over others, and prefer their favorite components to work and operate with a number of different process controllers, HMI solutions and applications. Since the early 1990s, many modern process control systems have evolved from closed proprietary systems to more convenient connected and open systems. However, the open components of modern control systems have been focused on specific applications or networking communication protocols for such systems. The general aspects of the controller and its programming, instructions and I / O and diagnostic behavior are still relatively closed and vendor-specific in their operation. Summary of the invention

[0004] The present disclosure provides an apparatus and system in which a process controller is decoupled from its supervisory layer.

[0005] In a first embodiment, a device is disclosed for use in an industrial process control and automation system operating using an open platform data communication protocol, the device comprising: a processor and a memory; and a communication interface connected to at least one process device and arranged to transmit instructions to the at least one process device and a data network of the industrial process control and automation system and receive data from the at least one process device. The communication interface is adapted to communicate using an open platform data communication protocol. A system repository file is stored in the memory, the system repository file containing process data information sent from the at least one process device to the device. The memory also contains: a stored function block definition file, the stored function block definition file containing function blocks defining a control strategy for controlling the at least one process device; and an engineering repository containing characteristics and parameters of function blocks associated with the at least one process device. The processor is operative to communicate the process data from the system repository file to the industrial process control and automation system using the open platform data communication protocol, and is operative to receive instructions from the industrial process control and automation system to execute the control strategy.

[0006] In a second embodiment, a system is disclosed for controlling at least one process instrument in an industrial process control and automation system that operates using an open platform data communication protocol, the system comprising a data network, at least one operator station connected to the data network, and at least one controller. The at least one controller comprises: a processor and a memory; and a communication interface connected to the at least one process instrument, arranged to transmit instructions to the at least one process instrument and the data network and receive data from the at least one process instrument, adapted to communicate using the open platform data communication protocol. A system repository file is stored in the memory and contains process data information sent from the at least one process instrument to the controller. The memory also comprises: a stored function block definition file, the stored function block definition file containing function blocks defining a control strategy for controlling the at least one process instrument; and an engineering repository containing characteristics and parameters of the function blocks associated with the at least one process instrument. The processor operates to communicate the process data from the system repository file to the operator station using the open platform data communication protocol, and operates to receive instructions from the operator station to execute the control strategy. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] For a more complete understanding of the present disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:

[0008] Figure 1 An exemplary industrial process control and automation system is illustrated;

[0009] Figure 2 illustrates details of an exemplary controller according to the present disclosure, showing internal components and functions of the exemplary controller;

[0010] Figure 3 An industrial process control system having a decoupled process controller according to the disclosed embodiments is illustrated; and

[0011] Figure 4 Details of the internal components and functions of a decoupled process controller in accordance with the disclosed embodiments are illustrated. DETAILED DESCRIPTION

[0012] The following discussion Figures 1 to 4 The various embodiments used to describe the principles of the present invention in this patent document are only by way of illustration and should not be construed as limiting the scope of the present invention. Those skilled in the art will appreciate that the principles of the present invention can be implemented in any type of appropriately arranged device or system.

[0013] Distributed process control systems built today are integrated into functional control layers, each of which provides a system of control ranging from a local control level to an enterprise control level. At the first level, process instruments and sensors are controlled by local controllers. Data from connected sensors and commands to controllers are typically transmitted to / from the supervisory control layer over a network. The supervisory control layer uses supervisory servers to record information collected or generated by the controllers, such as status information related to the operation of process elements. The servers can also execute application programs that control the operation of the controllers, generate functional control blocks for executing control strategies, and thereby control the operation of process elements. One or more operator stations coupled to the servers provide user access to the servers, which in turn provide user access to the controllers and process elements.

[0014] In the past, due to hardware, memory, processing power and bandwidth constraints, supervisory controllers of the control system as well as engineering control services required the use of dedicated servers to perform these functions of the control system. This embodiment contemplates a distributed control system architecture that decouples the supervisory layer and supervisory servers from the process controllers, thereby allowing the control application and engineering database to reside in memory in the process controllers, thereby allowing the embedded processors contained in the process controllers to perform control of the process elements of the system.

[0015] Figure 1 An exemplary distributed process control system architecture 100 is illustrated that is currently used to provide control of a manufacturing process. Figure 1 The embodiment of the process control system 100 shown is for illustration only. Other embodiments of the process control system 100 may be used without departing from the scope of the present disclosure.

[0016] In this exemplary embodiment, process control system 100 includes one or more process elements 102a-102b. Process elements 102a-102b represent the parts of any one of the functions of the execution of a wide variety of functions in the processing environment. For example, process elements 102a-102b can represent motors, valves and other industrial equipment in the processing environment. Process elements 102a-102b can represent any other parts or additional parts in the processing environment. Each process element in process elements 102a-102b includes any hardware, software, firmware or a combination thereof for performing one or more functions in the processing environment. Process elements 102a-102b can, for example, represent any parts, equipment or systems that can manipulate, change or otherwise process one or more materials in the processing environment. Two process controllers 104a-104b are coupled to process elements 102a-102b. Process controllers 104a-104b control the operation of process elements 102a-102b. For example, the controllers 104a-104b generally provide control signals to the process elements 102a-102b. Each of the controllers 104a-104b includes any hardware, software, firmware, or combination thereof for controlling one or more process elements 102a-102b.

[0017] Two servers 106a-106b are coupled to controllers 104a-104b. Servers 106a-106b perform various functions to provide supervisory support to the operation and control of controllers 104a-104b and process elements 102a-102b. For example, servers 106a-106b can record information collected or generated by controllers 104a-104b, such as state information related to the operation of process elements 102a-102b. Servers 106a-106b can also execute applications that control the operation of controllers 104a-104b, thereby controlling the operation of process elements 102a-102b. In addition, servers 106a-106b can provide secure access to controllers 104a-104b. Each server in servers 106a-106b includes any hardware, software, firmware or a combination thereof for providing access or control to controllers 104a-104b. Each of the servers 106a-106b may, for example, include one or more processors and one or more memories capable of storing data and instructions for use by the processors.

[0018] Due to storage limitations within controller products (such as dedicated hardened controller platforms), control execution events are typically transmitted to the supervisory servers 106a-106b in a timely manner. In addition, due to the nature of controller / server communications, there are times when the link or one or more of these platforms are unavailable. This may occur, for example, during a redundant server failover, redundant controller failover, or an interruption in the communication link between the controller and the server. Control events generated in the control execution environment are retained in an event buffer in the process controller 104a-104b and are sent to the supervisory server when the defined interrupt no longer exists.

[0019] One or more operator stations 108a-108b are coupled to the servers 106a-106b. The operator stations 108a-108b represent computing or communication devices that provide user access to the servers 106a-106b, which in turn may provide user access to the controllers 104a-104b and process elements 102a-102b. For example, the operator stations 108a-108b may allow a user to view the operation history of the process elements 102a-102b using information collected by the controllers 104a-104b and the servers 106a-106b.

[0020] The operator stations 108a-108b may also allow a user to adjust the operation of the process elements 102a-102b, controllers 104a-104b, or servers 106a-106b. Each of the operator stations 108a-108b includes any hardware, software, firmware, or combination thereof for supporting user access and control of the system 100. Each of the operator stations 108a-108b may, for example, include one or more processors and one or more memories capable of storing data and instructions used by the processors.

[0021] In this example, at least one of the operator stations 108b is a remote station. The remote station is coupled to the servers 106a-106b via a remote network 110. The network 110 facilitates communication between various components in the system 100. For example, the network 110 may convey Internet Protocol (IP) packets, frame relay frames, asynchronous transfer mode (ATM) cells, or other suitable information between network addresses. The network 110 may include all or part of one or more local area networks (LANs), metropolitan area networks (MANs), wide area networks (WANs), a global network (such as the Internet), or any one or more other communication systems at one or more locations.

[0022] In this example, the system 100 includes two additional servers 112a-112b. The servers 112a-112b execute various applications to control the overall operation of the system 100. For example, the system 100 may be used in a processing or production plant or other facility, and the servers 112a-112b may execute applications for controlling the overall operation of the plant or other facility. As a specific example, the servers 112a-112b may execute applications such as enterprise resource planning (ERP), manufacturing execution system (MES), or any other or additional plant or process control applications. Each of the servers 112a-112b includes any hardware, software, firmware, or combination thereof for controlling the overall operation of the system 100. Each of the servers 112a-112b may, for example, include one or more processors and one or more memories capable of storing data and instructions used by the processors.

[0023] like Figure 1 As shown, the system 100 includes various redundant networks 114a-114b and a single network 116a-116c that support communications between components in the system 100. Each of these networks 114a-114b, 116a-116c represents any suitable network or combination of networks that facilitate communications between components in the system 100. The networks 114a-114b, 116a-116c may represent, for example, Ethernet networks.

[0024] In one aspect of operation, a control process is implemented by the controllers 104a-104b, and the control process is constructed using function blocks 118. Function blocks 118 represent executable software objects that perform specific tasks. Each function block 118 may also be graphically represented by a symbol and have specified parameters (such as one or more inputs and / or one or more outputs). To define a control process, a user may select a particular function block 118 and link the inputs and outputs of the selected function block 118. The controllers 104a-104b may then implement the defined control process.

[0025] Any suitable type and number of function blocks 118 may be present in the system 100. Function blocks 118 may, for example, include "component blocks" that represent basic functions. These basic functions may be combined into larger function blocks called "container blocks." "Independent blocks" refer to function blocks that do not contain component blocks and are not contained within container blocks. These blocks merely represent examples of the types of function blocks 118 that may be used in the system 100. Other or additional types of function blocks 118 may be used in the system 100.

[0026] Different types of function blocks 118 are associated with different block definition files 120. The block definition files 120 define various characteristics of the associated type of function blocks 118. For example, the block definition files 120 may define parameters (such as inputs and outputs) for one type of function block 118. The block definition files 120 may also define symbols that graphically represent one type of function block 118. The block definition files 120 may further define a form layout for one type of function block 118, wherein the form layout is later used by a user to configure the function block 118 for use in a control process.

[0027] In this example, the block definition file 120 is stored in a database 122. The database 122 includes any hardware, software, firmware, or combination thereof for storing information and facilitating retrieval of the information. The database 122 may use any of a variety of data structures, arrangements, and compilations to store information and facilitate retrieval of the information. In some embodiments, the database 122 represents an engineering repository database (ERDB).

[0028] The control process is constructed with function blocks 118 using a process builder application 124. The process builder application 124 provides a graphical user interface that allows a user to create or edit a control process using graphical symbols representing the types of function blocks 118. For example, the process builder application 124 may allow a user to select a specific type of function block that presents the user with graphical symbols representing the selected type of function block. The user may then link the inputs and outputs of the selected type of function block. An instance of the selected function block type (function block 118) may then be created and used to implement the control process. The process builder application 124 includes any hardware, software, firmware, or combination thereof for creating or editing a control process. The process builder application 124 may, for example, represent a control builder application from Honeywell International.

[0029] As noted above, conventional process control systems typically lack mechanisms for allowing users to create or edit function block types or parameters associated with function block types. According to the present disclosure, a user is able to access a function block editor 126. The block editor 126 provides a graphical user interface that allows a user to create or edit function block types and to create or edit parameters associated with function block types. For example, the block editor 126 may allow a user to create, edit, or delete a block definition file 120, which allows the user to control which types of function blocks 118 are transmitted to the controllers 104a-104b for use in the process control system 100.

[0030] In a specific embodiment, the block editor 126 can be used to create or edit the custom algorithm function block type, custom data block type and function block type of the Foundation Fieldbus device. The custom algorithm block contains a user-defined algorithm and a user-defined data structure. The custom data block supports user-defined data parameters. The Foundation Fieldbus block is used together with the device supporting the Foundation Fieldbus technology, which supports the dynamic integration of special field devices with digital-based control systems. Then the process builder application 124 can be used to combine the instances of these function block types defined by the user into the control process. This only represents several examples of the types of function blocks that can be created, edited or deleted using the block editor 126. The block editor 126 can be used to create, edit or delete any other or additional type of function block. As a specific example, the block editor 126 can be used to create, edit or delete the proprietary function block type used in the system or controller.

[0031] The block editor 126 includes any hardware, software, firmware, or combination thereof for creating or editing a function block type or its associated parameters. The block editor 126 may be implemented, for example, as an Active-X control.

[0032] Figure 2 An example of a controller 200 according to the present disclosure is illustrated. The process controller 200 may represent, for example, Figure 1 However, the device 200 may be used in any other suitable system and may represent any suitable device in the system.

[0033] like Figure 2 As shown, the controller 200 includes at least one processor 202, at least one storage device 204, at least one communication unit 206, and at least one input / output (I / O) unit 208. Each processor 202 can execute instructions, such as those that can be loaded into the memory 210. Each processor 202 represents any suitable processing device, such as one or more microprocessors, microcontrollers, digital signal processors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or discrete circuits. The processor 202 will execute any suitable instructions, such as those that implement control and supervision of the process elements 102a-102b.

[0034] Memory 210 and persistent storage 212 are examples of storage devices 204, which represent any structure capable of storing information (such as data, program code, and / or other suitable information, whether temporary or permanent) and facilitating the retrieval of information. Memory 210 may represent random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 212 may include one or more components or devices that support longer-term storage of data, such as read-only memory, a hard drive, a flash memory, or an optical disk. In the present disclosure, persistent storage 212 includes databases 230 and 240, which include any hardware, software, firmware, or combination thereof for storing information and facilitating the retrieval of information. Databases 230 and 240 may use any of a variety of data structures, arrangements, and compilations to store information and facilitate the retrieval of information.

[0035] The communication unit 206 supports communication with other systems or process instruments and devices. For example, at least one communication unit 206 may include one or more wired communication networks that support data communication over any suitable physical or communication link using any number or form of communication protocols for communicating with process instruments, such as FOUNDATION Fieldbus, HART, PROFIBUS, and MODBUS. The communication unit 206 also connects the controller 200 to a data communication network, such as the networks 114a-114b that support communication between components in the system 100.

[0036] I / O unit 208 allows input and output of data and commands to the network. For example, unit 206 can provide a connection for user input to an operator station via a keyboard, mouse, keypad, touch screen, or other suitable input device. Unit 206 can also send output to a display, printer, or other suitable output device.

[0037] Figure 3 Components of an industrial automation system architecture with decoupled controllers according to one or more embodiments are illustrated. Figure 3 As shown, the industrial automation system 300 is organized into three main layers, namely, an open platform layer, a factory network layer, and a factory control layer. The factory control layer may include one or more process instruments or devices, such as sensors, actuators, flow meters, pressure and temperature transmitters, and other devices operating in a processing facility, as well as controllers and wireless gateways. The controller 304 provides local and supervisory control of one or more wired process instruments or devices 330a-330c through a wired network 335 operating according to one or more bus protocols (such as Foundation Fieldbus, PROFIBUS, HART, or MODBUS). The controller 304 can be a single controller or a dual redundant controller pair operating in a single network configuration or a dual redundant network configuration.

[0038] The controller 305 provides local and supervisory control of one or more wireless process instruments or devices 320a-320c through a wireless gateway device 325. The wireless gateway 325 wirelessly sends and receives data to the wireless process instruments or devices 320a-320c using a wireless network 350 using one or more industrial wireless communication protocols such as WirelessHART and ISA100. The controller 305 can also be a single controller or a dual redundant controller pair operating in a single network configuration or a dual redundant network configuration.

[0039] The network layer 314 may include any suitable wired or wireless network, such as, for example, a local area network (LAN), a wide area network (WAN), Ethernet, Wireless Fidelity (WiFi), IEEE 802.11, or ISA 100. As a specific example, the network 314 in this embodiment represents a pair of redundant Ethernet networks, such as the Fault Tolerant Ethernet (FTE) network from HONEYWELL INTERNATIONAL INC.

[0040] The plant network layer may also be connected to a cloud network 340 and one or more remote operator stations 341. The remote stations 341 are coupled to the plant network layer 314 via the cloud network 340. The cloud network 340 facilitates communication between various components in the system 300, including controllers 304, 305, modules 312a-312c, and operator stations 307, 308. For example, the network 340 may convey Internet Protocol (IP) packets, frame relay frames, asynchronous transfer mode (ATM) cells, or other suitable information between network addresses. The cloud network 340 may include all or part of one or more local area networks (LANs), metropolitan area networks (MANs), wide area networks (WANs), a global network (such as the Internet), or any one or more other communication systems at one or more locations. In addition, the cloud network 340 may also support any open data communication protocol such as the OPC UA (Open Platform Connectivity Unified Architecture) data protocol and its core services for synchronous and asynchronous data publishing, alarm and event publishing, historical data transmission, etc.

[0041] The open platform layer includes at least an analysis module 312a, a history record module 312b, and an advanced control module 312c, as well as an operator station 308 running any suitable HMI software application. Modules 312a-312c provide various functions to the overall operation of the system 300. For example, the analysis module 312a can be used to provide a tool for predictive analysis to deliver insights about future performance based on historical data. The history record module 312b acts as a repository for process data from the controllers 304, 305, process equipment and devices 330a-330c, 320a-320c of the system 300. The historical data stored in the history record 312b can be retrieved by other modules of the open platform layer as well as the operator station 308 and the remote station 341 through the cloud network 340. For example, historical data can be used as a basis for predictive analysis and can also be used by the advanced control module 312c to develop advanced software models. The task of the advanced control module 312c is to implement model predictive control (MPC) or other advanced predictive control (APC) models that can be sent to one or more controllers to control process equipment and other devices using the models and predictions developed by the module 312c. Each of the modules 312a-312c includes any hardware, software, firmware, or combination thereof for the overall operation of the control system. Each module 312a-312c of the open platform layer can be configured as a single or multiple server platforms and can include, for example, one or more processors and one or more memories capable of storing data and instructions used by the processors. Even if Figure 3 While the modules 312a - 312c are illustrated as being locally connected in a factory via a factory network 314 , the modules 312a - 312c may also be located at a remote location and connected to the system 300 via a cloud network 340 .

[0042] The open platform layer also includes an operator station 308. Station 308 represents a computing or communication device that provides user access to the components and equipment of system 300. For example, operator station 308 may allow a user to view the operation history of process equipment and devices stored in historian 312b and collected by controllers 304 and 305 on an included display. The operator station 308 may also execute a software program to allow the user to run "pattern-based discovery and predictive process analytics" using data from analysis module 312a.

[0043] The operator station 308 uses a human machine interface (HMI) software application to implement overall user communications and control of the system 300. The HMI represents a software application whose task is to provide user access to the open platform layer and its modules, as well as access to the plant control layer and its controllers, process instruments and equipment. For example, the HMI may allow users and operators of the system 300 to adjust the operation of process instruments and equipment and controllers. The HMI will include any hardware, software, firmware, or combination thereof for supporting user access and control of the system 300. The HMI may, for example, provide advanced process control from an advanced control module implementing model predictive control (MPC) or other advanced predictive control (APC) to one or more controllers to control process instruments and other equipment in real time using models and predictions developed by the advanced control modules.

[0044] Go to Figure 4 , illustrates a controller 304 of the present disclosure. For the purpose of this embodiment, controller 304 will be used to explain the operation of the decoupling controller. Controller 305 is also a decoupling controller and includes the same internal components as controller 304 and operates in the same manner as controller 304. Controller 304 includes processor 202, memory 210, storage device 204, I / O unit 208, communication unit 206 and controller bus 200. Controller bus 200 provides a unified bidirectional high-speed system bus that provides data connections, address connections and memory connections to the components and devices of controller 304. Communication unit 206 supports data communication with other system and process instruments and devices 330a-330c through a network bus 335, which uses any suitable bus protocol, such as Foundation Fieldbus, PROFIBUS, HART or MODBUS. The communication unit 206 also provides network data communications to the platform layer through the network 314 to user-operated input / output devices (such as data terminals, displays, printers) or other suitable communication devices (such as operator stations 307, 308 and remote stations 341).

[0045] The processor 202 of the controller 304 may run command and control applications, streaming and batch analytics, and send device-generated telemetry data to the open platform layer via the communication unit 206 and the plant network 314. Similarly, data originating from the open platform layer may be sent to process instruments and equipment (e.g., devices 330a-330c) via the controller 304, such as, for example, MPC and APC control and command data and instructions to connected devices and sensors.

[0046] The controller 304 of the present embodiment includes an open protocol data communication and security software application 225 stored in the persistent storage device 212, which operates as a common protocol machine and is arranged to deliver downstream connections to the plant control layer and other devices and systems using an open communication protocol. In addition, the open protocol data communication and security software 225 is arranged to provide upstream connections to modules 312a-312c, operator stations 308 and other devices of the open platform layer connected to the plant network 314, as well as any remote stations or other devices connected to the cloud network 340. The data collected from the downstream protocol is mapped to a unified abstraction layer that provides a consistent namespace and data services for information publishing to the modules 312a-312c and operator stations 308 associated with the open platform layer.

[0047] In the past, each software or application developer needed to write a custom interface (or server / driver) to exchange data with hardware process instruments and devices. Industrial open protocol standards replace this convention by providing a common interface that allows this work to be done once and then easily reused by HMI and custom applications.

[0048] For example, the Open Platform Connectivity (OPC) specification is based on Microsoft Object Linking and Embedding OLE (now ActiveX), Component Object Model (COM), and Distributed Component Object Model (DCOM) technologies. DCOM provides a set of interfaces that allow clients and servers to communicate within the same computer running compatible operating systems. OPC defines a set of standard interfaces, properties, and methods for use in process control, manufacturing, and automation applications. These applications include distributed control systems, programmable logic controllers, input / output (IO) systems, intelligent field devices, and other real-time information servers. ActiveX / COM technology defines how individual software components interact and share data. By using Microsoft Visual Basic object-oriented components, OLE Automation, OPC can provide plant floor data to office applications over a local area network (LAN), remote sites, or the Internet.

[0049] The OPC protocol provides many benefits to end users and hardware and software manufacturers, including open connectivity, high performance, and improved supplier productivity and security. OPC provides open connectivity, allowing users to choose from a wider variety of plant floor devices and client software, thereby allowing better utilization of the best-in-breed applications. Because OPC is an open standard, software and hardware manufacturers spend less time on connectivity issues and more time on application issues, thereby eliminating a lot of duplication of effort. OPC promotes greater interoperability between automation and control applications, field devices, and commercial and office applications. Other open protocol data communication protocols can be used to communicate in the system 300, including, for example, Ethernet / IP, ProfiNet, IEC-61850, Modbus / TCP, HART / IP, etc.

[0050] Processor 202 uses a communication stack that supports the Open Platform Connectivity Unified Architecture (OPC UA) data protocol and its core services to enable synchronous and asynchronous data publishing, alarm and event publishing, historical data transmission, blind record or "BLOB" transmission, etc. The OPC UA architecture is platform and operating system independent because it does not rely on DCOM technology to communicate between components of the system. OPC UA also includes security features, including encryption and certificate-based authentication. Security services are available for its devices to bidirectionally provide secure protection traffic flows to protect both open platform layer modules and operator stations as well as the platform, network connections, and control layers of plant control layer systems and devices. As an alternative to OPC UA or in addition to OPC UA, other open platform protocols may be supported.

[0051] The present embodiment decouples the supervisory layer and supervisory servers 106a-106b from the process controllers 304, 305. The control applications, engineering databases, and names and name services that previously resided in the supervisory servers 106a-106b now reside in the persistent storage 212 of the controller 304. The persistent storage 212 includes databases 230 and 240, which include any hardware, software, firmware, or combination thereof for storing information and facilitating retrieval of information.

[0052] The database 230 performs the functions of the supervisory servers 106a-106b. In this embodiment, the database 230 acts as a system repository that is configured to record information collected or generated by the controller 304, such as status information related to the operation of the process equipment, into the memory file 232. The information collected and stored in the memory file 232 is uploaded to the network 314 through the communication unit 206 for storage and use by the modules 312a-312b and for access by the operator station 308.

[0053] Names and name services are provided by the executable software application 252 and are also stored in the system repository database 230 along with supporting translation libraries for this service. The names and name services application 252 provides plain text name references for use directly with the controller 304 to access control objects or other configuration data without using specific control object identifiers. For example, a library of controller objects and functions is maintained in the database 230 that supports the operation of the controller 304 (such as function blocks, algorithms, processes, or any other executable elements). In addition, names and name services can support access using plain text messaging, alarm functions, properties / parameters, tags, and improved control functions for process instruments and equipment connected to the controller 304. The translation library is built on the control execution environment of the controller 304.

[0054] The database 240 stores executable software applications that control the operation of the controller and includes function block definitions 220 for the function control blocks 218. The function blocks 218 implement control strategies to control the operation of process equipment and devices connected to the controller 304. Figure 1 As explained, a function block 218 represents an executable software object that performs a specific task. Each function block 218 may also be graphically represented by a symbol and have specified parameters (such as one or more inputs and / or one or more outputs). To define a control process, a user may select a specific function block 218 and link the inputs and outputs of the selected function block 218.

[0055] Any suitable type and number of function blocks 218 may be stored in persistent memory 212. Function blocks 218 may, for example, include "component blocks" that represent basic functions. These basic functions may be combined into larger function blocks called "container blocks." "Independent blocks" represent function blocks that do not contain component blocks and are not contained within container blocks. These blocks represent only examples of the types of function blocks 218 that may be used by controller 304.

[0056] Different types of function blocks 218 are associated with different block definition files 220. The block definition files 220 define various characteristics of the associated type of function blocks 218. For example, a block definition file 220 stored in the database 240 may define parameters (such as inputs and outputs) for one type of function block 218. The block definition file 220 may also define symbols that graphically represent one type of function block 218. The block definition file 220 may further define a form layout for one type of function block 218, wherein the form layout is later used by a user to configure the function block 218 for use in a control process.

[0057] In this embodiment, the block definition file 220 is stored in a database 240. The database 240 includes any hardware, software, firmware, data structure or arrangement, or combination thereof, for storing information and facilitating retrieval of information. In some embodiments, the database 240 represents an engineering repository database (ERDB).

[0058] exist Figure 1 In an example of a system 100, a process builder application 124 maintained in a supervisory server 106a-106b is used to build control instructions for a function block 118. The process builder application 124 provides a graphical user interface that allows a user to create or edit a control process using graphical symbols representing the type of function block 118. For example, the process builder application 124 may allow a user to select a specific type of function block that presents the user with graphical symbols representing the selected type of function block. The user may then link the inputs and outputs of the selected type of function block. An instance of the selected function block type (function block 118) may then be created and used to implement the control process. The process builder application 124 includes any hardware, software, firmware, or combination thereof for creating or editing a control process. The process builder application 124 may, for example, represent a control builder application of Honeywell International.

[0059] However, in an embodiment of the system 300, an operator station 307 is used to connect the controller 304 to a process builder application 224 executed in the operator station 307. A user may use the process builder application 224 to create or edit a function block 218 using data stored in the ERDB 220. The process builder application 224 may allow a user to create, edit, or delete a block definition file 220, thereby controlling which types of function blocks 218 are controlled by the controller 304. The operator station 307 and the process builder application 224 are connected to the controller 304 via a network layer 314.

[0060] Data communications and security application software stored in persistent storage 225 provides core security for the plant control layer's equipment controller 304. The open protocol application 225 works in conjunction with the communication unit 206 to perform deep packet inspection of incoming traffic from the network 314 and the operator station 307, and from the operator station 341 and the network 314 through the cloud network 340.

[0061] Since each controller 304 in the plant control layer includes an open protocol communication and security application 225, the controller can use the plant network layer 314 to provide flexible scalability and deployment within the plant control layer. For example, new controllers and other control devices can be added to the plant control layer by connecting the controllers and devices to the network 314 without configuring a supervisory server to handle the new devices. An industrial or commercial protocol based on an open standard internal protocol (IP) decouples the controller from the supervisory system, making each controller independent of any supervisory device or server. For example, the controller 304 of the present embodiment can be integrated into the industrial plant control layer and operated from the operator station 308 HMI through the network 314. Upstream and downstream data processing and security are implemented by the open protocol application 225 using at least one open protocol (such as Ethernet / IP, OPC UA, ProfiNet, IEC-61850, Modbus / TCP, HART / IP, etc.) to connect the controller 304 to the HMI.

[0062] Additionally, the plant control layer and controllers 304 using at least one open data communication and security protocol may operate in a hybrid configuration capable of reaching devices and operator stations over the network 314 and communicating to devices and remote stations using an open platform protocol connected via the cloud network 340 .

[0063] Although Figure 4 This is an example of a decoupling controller 304, but may be used for Figure 4 Various changes may be made. For example, the components and functions of controller 304 may have a wide variety of configurations. Figure 4 The illustrated controller 304 is intended to illustrate one example and type of a decoupling controller and does not limit the present disclosure to any particular type of controller configuration.

[0064] Controller 305 operates in a similar manner to controller 304, however, Figure 3 As illustrated, the controller 305 is connected to a wireless gateway 325 via a wired network connection 336. The wireless gateway 325 includes at least one radio wave device that operates using an industrial wireless protocol such as, for example, WirelessHART or ISA100. The wireless gateway 325 transmits data and command signals to the wireless process devices 320a-320c via a wireless network 350. Sensor and process data are then transmitted from the wireless process devices 320a-320c to the wireless gateway 325 via the wireless network 350. The wireless gateway transmits the data received on the wireless network 350 to the controller 305 via the network connection 336 for processing by the open platform layer.

[0065] In some embodiments, the various functions described in this patent document are implemented or supported by a computer program formed by a computer. This embodiment envisions a distributed control system architecture that decouples the supervisory layer and supervisory server from the process controller, thereby allowing the control application and engineering database to reside in the memory in the process controller, thereby allowing the embedded processor of the process controller to perform control of the process elements of the system, embodied in the control of the readable program code in the computer-readable medium. The phrase "computer-readable program code" includes any type of computer code, including source code, object code and executable code. The phrase "computer-readable medium" includes any type of medium that can be accessed by a computer, such as a read-only memory (ROM), a random access memory (RAM), a hard drive, a compact disc (CD), a digital video disc (DVD) or any other type of memory. "Non-transient" computer-readable media excludes wired, wireless, optical or other communication links that transmit instantaneous electrical signals or other signals. Non-transient computer-readable media include media that can permanently store data and media that can store and rewrite data afterwards, such as rewritable optical discs or erasable memory devices.

[0066] It may be advantageous to set forth the definitions of certain words and phrases used throughout this patent document. The terms "application" and "program" refer to one or more computer programs, software components, instruction sets, processes, functions, objects, classes, instances, related data or a portion thereof that are suitable for implementation with suitable computer code (including source code, object code or executable code). The term "communication" and its derivatives cover both direct communication and indirect communication. The terms "include" and "comprise" and their derivatives mean including but not limited to this. The term "or" is inclusive, meaning and / or. The phrase "associated with..." and its derivatives may mean including, included within, interconnected with, contained within, connected to or connected with, coupled to or coupled with, communicable with, collaborate with, interlaced, juxtaposed, close to, coupled to or coupled with, having, having the property of, having a relationship with, or having a relationship with. When used with a list of items, the phrase "at least one of..." means that different combinations of one or more of the listed items may be used, and only one item in the list may be required. For example, “at least one of A, B, and C” includes any combination of A, B, C, A and B, A and C, B and C, and A, B, and C.

[0067] The description in this application should not be construed as implying that any particular element, step, or function is an essential or critical element that must be included within the scope of the claims. The scope of subject matter protected by a patent is limited only by the claims as allowed. In addition, none of the claims is intended to invoke 35 U.S.C. §112(f) with respect to any of the appended claims or claim elements, unless the exact words "means for..." or "step for..." followed by a participle phrase identifying the function are expressly used in a particular claim. The use of terms such as (but not limited to) "mechanism", "module", "device", "unit", "component", "element", "member", "device", "machine", "system", "processor" or "controller" within the claims is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 U.S.C. §112(f).

[0068] Although the present disclosure has described certain embodiments and generally associated methods, changes and permutations of these embodiments and methods will be apparent to those skilled in the art. Therefore, the above description of the exemplary embodiments does not limit or restrict the present disclosure. Other changes, substitutions and variations are also possible without departing from the spirit and scope of the present disclosure as defined in the following claims.

Claims

1. An apparatus for use in an industrial process control and automation system operating using an open platform data communications protocol, the apparatus comprising: Processor and memory; a communication interface connected to at least one process device, the communication interface being arranged to transmit instructions to and receive data from the at least one process device and a data network of the industrial process control and automation system, the communication interface being arranged to communicate using an open platform data communication protocol; a system repository file stored in the memory, the system repository file containing process data information transmitted from the at least one process instrument to the device; a function block definition file stored in the memory, the function block definition file including function blocks defining a control strategy for controlling the at least one process device; an engineering repository file stored in the memory, the engineering repository file containing characteristics and parameters of the function blocks associated with the at least one process instrument; and wherein the processor is operative to communicate the process data from the system repository file to the industrial process control and automation system using the open platform data communication protocol, and is operative to receive instructions from the industrial process control and automation system to execute the control strategy, the industrial process control and automation system decoupling the device from a supervisory layer and a supervisory server, and allowing the engineering repository file to reside in the memory of the device to execute control of the at least one process instrument of the industrial process control and automation system. The apparatus of claim 1 , wherein the memory is a persistent storage device.

3. The apparatus of claim 2, wherein the persistent storage device comprises: a system repository database including the system repository files, the system repository database storing and recording information collected or generated by the device related to the operation of the at least one process instrument; as well as A name and name software application includes a name and name service for providing a plain text name reference used by the device to access function block control objects or other configuration data without using a specific function block identifier.

4. The apparatus of claim 2, wherein the persistent storage device comprises: An engineering repository database comprising the engineering repository files stores block definition files defining the properties of associated function blocks.

5. The apparatus of claim 2, wherein the persistent storage device comprises: A data communications and security software application manages the open platform data communications protocol, the data communications and security software application comprising a communications stack used by the processor to support the OPC UA open platform data communications protocol.

6. A system for controlling at least one process instrument in an industrial process control and automation system operating using an open platform data communications protocol, the system comprising; Data network; at least one operator station connected to the data network; as well as At least one controller, the at least one controller comprising: (a) processor and memory; (b) a communication interface connected to the at least one process instrument, the communication interface being arranged to transmit instructions to the at least one process instrument and the data network and to receive data from the at least one process instrument, the communication interface being adapted to communicate using the open platform data communication protocol; (c) a system repository file stored in the memory, the system repository file containing process data information sent from the at least one process instrument to the at least one controller; (d) a function block definition file stored in the memory, the function block definition file including function blocks defining a control strategy for controlling the at least one process device; (e) an engineering repository file stored in the memory, the engineering repository file containing characteristics and parameters of the function blocks associated with the at least one process device; and wherein the processor is operative to communicate the process data from the system repository file to the operator station using the open platform data communications protocol, and is operative to receive instructions from the operator station of the industrial process control and automation system to execute the control strategy, the industrial process control and automation system decoupling the controller from a supervisory layer and a supervisory server and allowing the engineering repository file to reside in a memory of the controller to execute control of the at least one process instrument of the industrial process control and automation system.

7. The system of claim 6, wherein the memory is a persistent storage device, wherein the persistent storage device comprises: a system repository database including the system repository files, the system repository database storing and recording information collected or generated by the at least one controller related to the operation of the at least one process instrument; a name and name software application including a name and name service for providing a plain text name reference used by the at least one controller to access a function block control object or other configuration data without using a specific function block identifier; an engineering repository database including the engineering repository files, the engineering repository database storing block definition files defining characteristics of associated function blocks; as well as a data communications and safety software application to manage the open platform data communications protocol, the data communications and safety software application comprising a communications stack executed by the processor to support the OPC UA open platform data communications protocol and its core services to enable synchronous and asynchronous data transfer between the at least one controller and the at least one operator station.

8. The system of claim 6, wherein the operator station includes an HMI to allow overall user communication and control of the system and receives data from the at least one controller to manage the operation of the at least one controller and process equipment.

9. The system of claim 8, wherein the data network is connected to a cloud network and at least one remote operator station.

10. The system of claim 7 wherein a second operator station is connected to the data network, the second operator station including a process builder software application, the process builder software application being operated by a user to create and edit the function blocks defined in the function block definition file using the data stored in the engineering repository database.

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