Process control system

Abstract

A process control system includes at least one module terminal unit, at least one adapter module disposed on the module terminal unit and configured to communicate with a field device, and at least one controller module disposed on the adapter module and configured to communicate with the field device. And a controller module arranged on the module terminal unit and configured to process data from the adapter module, where the adapter module and the controller module are connected to each other by a peer-to-peer connection, in particular by the module terminal unit.

Description

Technical Field

[0001] The present invention relates to a process control system, in particular to a process control system for an input / output system. Background Art

[0002] Process control systems are well known in the prior art. A process control system may include several different hardware units. For example, in the process industry or the automotive industry, a process control system may be used to control a complex production plant. In practice, a process control system includes several different field devices that are connected to I / O modules on a module terminal unit. The I / O signals of a process control system are collected and distributed by remote I / O systems that are usually installed very close to the automated process. These remote I / O systems are connected to the process control system via a fieldbus. The conversion of fieldbus signals into controller-readable / processable / understandable data objects will be performed in a unit referred to as a fieldbus communication interface (FCI) or sometimes referred to as a communication interface (CI).

[0003] Control equipment for process automation needs to be available as products and services as spare parts for a long time, but the electronic market changes much faster. In the case where hardware components have to be updated, the multiple variants of the fieldbus communication interface hardware for each fieldbus type must be redesigned, which results in a huge maintenance effort.

[0004] For the reasons stated above, it is now apparent that a need exists to provide an alternative process control system.

[0005] These and other objects which become apparent from reading the following description are solved by the subject-matter of the independent claims. The dependent claims relate to preferred embodiments of the invention. Summary of the invention

[0006] According to aspects of the present invention, a process control system is provided, comprising: at least one module terminal unit; at least one adapter module, which is arranged on the module terminal unit and configured to communicate with a field device; and at least one controller module, which is arranged on the module terminal unit and configured to process data from the adapter module; wherein the adapter module and the controller module are connected to each other via a peer-to-peer connection, in particular, via the module terminal unit.

[0007] The module terminal unit may also be described as a mounting terminal unit. The module terminal unit may also be described as a base plate or backplane. The module terminal unit is configured to hold an adapter module and a control module. More modules (e.g., a power module) may be arranged at the module terminal unit. The module terminal unit may include circuits for powering the modules and for data transmission between the modules.

[0008] The adapter module may preferably contain / comprise only the fieldbus specific transceiver and / or the hardware driver.The adapter module may be connected to an input / output module or I / O module, in particular a remote I / O module.

[0009] The adapter module and the control module are connected via a peer-to-peer connection. The peer-to-peer connection is provided by a module terminal unit. The peer-to-peer connection can also be described as a peer-to-peer adapter channel. The peer-to-peer connection can include any possible type of signal. The signal type of the peer connection can be an electrical single-ended signal, an electrical differential signal, a wireless signal, or an optical signal. The signal from the I / O device reaches the controller module via the peer-to-peer connection through the adapter module. The signal can also be described as field device data, because the data transmitted by the peer connection can originate from the field device.

[0010] The invention allows a high degree of flexibility in the selection of different fieldbus types. When a fieldbus is selected, it can be freely assigned to the controller modules. Moreover, certain signals of the peer-to-peer connection can be used to quickly detect the insertion, removal or failure of a new or different adapter module. Furthermore, bandwidth limitations caused by the electrical architecture no longer occur due to the peer-to-peer connection, especially compared to the bus architecture on the module terminal unit. To achieve these features, a universal CPU core can be used for all fieldbus types.

[0011] In an embodiment, the control module is connected to multiple adapter modules via a peer-to-peer connection. This allows multiple field devices to be controlled simultaneously. In particular, multiple devices with the same and / or different fieldbus protocols.

[0012] In an embodiment, the adapter module is connected to multiple controller modules via a peer-to-peer connection. In this way, different settings can be made. In addition, for redundancy reasons, one controller module can be used as a backup controller module.

[0013] In an embodiment, at least one controller module of the plurality of controller modules is a redundant controller module. By doing so, possible stagnation can be prevented.

[0014] In an embodiment, the peer connection includes multiple peer signal channels, in particular bidirectional channels and / or unidirectional channels. More precisely, a set of peer wiring is combined into a peer connection or peer adapter channel together with a number of differential and single-ended signals. For some connections, multiple signals must be provided / are possible. For example, in order to control the RS485 transceiver / driver for PROFIBUSDP, three signals are required: transmission, reception, and direction control. In a different example, in order to control the ABB module bus, five signals are required: transmission, reception, direction control, synchronization clock, and synchronization clock enable.

[0015] In an embodiment, the adapter module comprises a selector element configured to select one of the plurality of peer connections. This means that the selector element is configured to switch between different peer connections. The selector element may be a software logic or a hardware element.

[0016] In an embodiment, the adapter module comprises a configuration element configured to control the selector element.The configuration element may be connected to the control module to control which peer connection the selector element should switch to.

[0017] In an embodiment, the control module comprises a configuration unit, wherein the configuration unit is configured to communicate with a configuration element of the adapter module. The configuration unit is configured to control the configuration element of the adapter module. The configuration unit may also be described as a configuration manager. The configuration unit communicates with the configuration element.

[0018] In an embodiment, the selector element of the adapter module comprises a 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 elements and the configuration unit or units may be connected to each other via 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 are multiple bus connections.

[0019] The module terminal unit preferably comprises a plurality of peer adapter channels. The flexible allocation of adapter modules to control modules can be established by the selector element according to application requirements. As described above, the control module and the adapter module are each connected using a service bus for setting the selector element to the desired / selected peer connection.

[0020] In an embodiment, the adapter module and the controller module are separate hardware components. This allows any module to be switched or repaired individually. Alternatively, the adapter module hardware and the control module hardware can be placed in the same module housing. The adapter module can then be connected directly to the controller module without the need for a connection in the module terminal unit.

[0021] In an embodiment, the peer connection is achieved by wiring in the module terminal unit. More specifically, the wiring is embedded inside the module terminal unit and / or embedded on the module terminal unit. For example, the wiring can be embedded in the type of board or module terminal unit.

[0022] In an embodiment, the wiring of the peer connections in the module terminal unit is passive wiring, which means that the wiring can be universal.

[0023] In an embodiment, the adapter module includes a transceiver element for one or more fieldbuses.The transceiver element may be used to convert a signal from an I / O device so that the signal may be sent over a peer-to-peer connection.

[0024] In an embodiment, the control module includes a fieldbus communication processor for one or more fieldbuses. The fieldbus communication processor may be composed of hardware elements and software elements. The fieldbus communication processor may be configured to process signals received by a peer connection. The fieldbus communication processor may include a CPU core with a memory and may be used for process automation control. The term CPU core may be broadly understood in the context of the present invention. The term "CPU core" may include all typical features of a modern digital processing system, such as a CPU, MCU, SoC, FPGA, DSP, and / or AI engine.

[0025] A fieldbus communications processor may have one or more fieldbus communications processor instances of the same or different fieldbus types. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this application. The accompanying drawings illustrate embodiments of the present invention and together with the description serve to explain the principle of the present invention. The accompanying drawings show:

[0027] Figure 1 is a schematic diagram of an embodiment of the present invention;

[0028] Figure 2 This is a schematic diagram of a peer connection;

[0029] Figure 3 is a schematic diagram of another embodiment of the present invention;

[0030] Figure 4 is a schematic diagram of another embodiment of the present invention;

[0031] Figure 5 is a schematic diagram of another embodiment of the present invention; and

[0032] Figure 6 is a schematic diagram of another embodiment of the present invention. DETAILED DESCRIPTION

[0033] Modern process control systems may include many different elements, and each embodiment shown in the figures includes only those elements that are relevant / necessary to that embodiment.

[0034] Figure 1This embodiment of a process control system 10 is shown. The process control system 10 includes a module terminal unit 11, two adapter modules 12, and a controller module 13. The adapter module 12 and the controller module 13 are arranged on the module terminal unit 11. In general, the process control system 10 may include a multi-module terminal unit 11 having a plurality of adapter modules 12 and a plurality of controller modules 13.

[0035] The adapter module 12 comprises a transceiver element 19. The transceiver element 19 may comprise a fieldbus specific transceiver and / or a hardware driver. This may also be described as a first hardware layer hardware.

[0036] The controller module 13 includes two fieldbus communication processors 20. The fieldbus communication processors 20 in the controller module 13 preferably handle all details of the fieldbus protocol. The controller module 13 also includes an actuator 22 or a process automation execution engine. The fieldbus communication processor 20 can be used to perform the actuator 22 and one or more instances of the same or different fieldbus types. The term "actuator" can be understood broadly. The actuator 22 can also be used to collect fieldbus / process data and distribute the fieldbus / process data to other components (connection elements) of the process control system 10.

[0037] The controller module 13 is connected to the adapter module 12 via a separate peer-to-peer connection 14. More precisely, both fieldbus communication processors 20 are connected to the transceiver element 19 of the adapter module 12 via the peer-to-peer connection 14. The peer-to-peer connection 14 is preferably at least partially arranged in the module terminal unit 11.

[0038] The peer connection 14 may also be described as a peer adapter channel. The peer connection 14 may not be limited to one signal. Instead, a group of signals are combined in one peer connection 14.

[0039] Figure 2 Such a peer connection 14 or peer adapter channel is shown. For example, signal 1 to signal 7 can be LVDS differential signals for better robustness and good communication performance. Auxiliary signal 8 to auxiliary signal 9 are single-ended signals for immediate detection of whether a component is ready or no longer available. The direction of the signal from the adapter module 12 to the controller module 13 can be freely configured depending on the fieldbus type.

[0040] An example of a fieldbus may include controlling an RS485 transceiver / driver for PROFIBUSDP. In this case, three signals are required for transmission, reception, and direction control. Another example of a fieldbus may include controlling an ABB module bus. Five signals are required for this. One signal each for transmission, reception, direction control, sync clock, and sync clock enable.

[0041] Figure 3 Another embodiment of a process control system 10 is shown. In this embodiment, the adapter module 12 and the controller module 13 each include a selector element 15. The adapter module 12 and the controller module 13 are connected to each other via a plurality of peer-to-peer connections 14.

[0042] The adapter modules 12 also each comprise a configuration unit 16, and the controller module 13 contains a configuration unit manager 17. The configuration unit and the configuration unit manager 17 are designed to communicate via a service bus connection 18, which may be arranged on the module terminal unit 11.

[0043] Preferably, the configuration unit manager 17 may act as a client on the service bus connection 18, while the configuration unit 16 may act as a server. The configuration unit manager 17 may know the desired settings of the selector element 15. This knowledge about the target settings may be specified from an engineering tool, or may be determined from an existing module in the module terminal unit 11. The configuration unit manager 17 controls the selector element 15 in the controller module 13 and sends the target settings to the corresponding configuration unit 16 in the adapter module 12. The configuration unit 16 in the adapter module 12 controls the selector element 15 according to the target settings. In other words, the selector element 15 switches to the desired peer connection 14 according to the target settings.

[0044] The configuration unit 16 and the selector element 15 adapter module can be implemented, for example, by programmable logic (for example, a field programmable gate array (FPGA) circuit). The signals of the peer connection 14 can be digital signals, which means that the selector element 15 can be implemented as a logic gate. The service bus connection 18 can be implemented, for example, by an I2C bus, and related FPGA-IP-cores are also possible. The size and complexity of such a selector element 15 and configuration unit 16 can be implemented in a small size. An important feature of the selector element 15 and the configuration unit 16 is that no fieldbus specific protocol knowledge needs to be implemented in the adapter module 12.

[0045] Figure 4Another embodiment is shown. The process control system 10 comprises three adapter modules 12 and two controller modules 13. The module terminal unit 11, the peer connections 14 with the adapter modules 12 and the controller modules 13, and the service bus connection 18 differ from the previous embodiment. Each controller module 13 comprises two selector elements 15. Each selector element 15 of the controller module 13 is connected to a selector element 15 of one of the adapter modules 12 via the peer connection 14. The selector element 15 comprises a plurality of peer connections 14, in particular three peer connections 14. Each adapter module 12 and the controller module 13

[0046] This allows flexible use of the adapter slot and allocation to controllers with spare resources. This flexibility is very helpful especially in the case of expansion and changes in process control applications.

[0047] Figure 5 An example is shown in which two controller modules 13 are assigned or connected to the same adapter module 12. One controller module 13 is the primary controller module, while the other controller module 13 is the backup controller module. Here, the functionality of the selector element 15 in the adapter module 12 can be extended, which selector element 15 can select / connect only one peer connection 14 to the controller module 13. These one to two relationships enable the construction of redundant controller systems. If the primary controller module 13 fails, the backup controller module 13 can immediately take over the active role to continue the process. There are options for implementing this functionality:

[0048] As a first option, if the primary controller module fails, the selector element 15 in the adapter module 12 immediately switches to the peer connection 14 of the backup controller module 13. The switching of the selector element 15 in the adapter module can be effected in different ways.

[0049] According to one approach, 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 .

[0050] According to another approach, the selector element 15 in the adapter module 12 has an automatic function to switch to the backup controller module 13 after detecting a specific predefined pattern of the auxiliary signal. The backup controller module 13 may also receive and detect the signal in a passive manner.

[0051] 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 as if the main controller module and the backup controller module 13 have their own transceiver element 19 on the same bus. This may lead to an impermissible state if one or both fieldbus communication processors 20 in the controller module 13 do not operate correctly according to the bus rules. However, this would also be the case if each controller module 13 had its own transceiver element 19 to the same fieldbus device. This functionality of the selector element would also allow the backup controller module 13 to detect the communication between the main controller module 13 and the I / O devices (remote I / O). By doing this, the backup controller module 13 gets the same process image of the I / O and can take over immediately in the event of a failure of the main controller.

[0052] Figure 6 Another embodiment of a process control system 10 is shown. Figure 5 The embodiment of FIG. 1 focuses on the redundancy of the controller module 13, but a failure of the adapter module 12 would stop communication with the I / O and is not taken into account. This can be achieved by Figure 6 The controller module 13 comprises an additional voting unit 21. The voting unit 21 is arranged between the selector element 15 and the fieldbus communication processor 20. The voting unit 21 can be implemented in a manner that can be used with an FPGA. The voting unit 21 can select which selector element 15 of the controller module 13 should be active.

[0053] Any disclosure and embodiment described herein refers to the process control system 10 listed above or below, and vice versa. The benefits provided by any embodiment and example are equally applicable to all other embodiments and examples, and vice versa.

[0054] By studying the drawings, the disclosure and the appended claims, other variations of the disclosed embodiments may be understood and implemented by those skilled in the art when practicing the claimed invention. 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 implement the functions of multiple items or steps recited in the claims. The 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 numerals in the claims should not be interpreted as limiting the scope.

[0055] References

[0056] 10Process Control System

[0057] 11-module terminal unit

[0058] 12 adapter modules

[0059] 13 Controller Module

[0060] 14Peer Connection

[0061] 15Selector element

[0062] 16 Configuration elements

[0063] 17 Hive

[0064] 18 Service Bus Connection

[0065] 19 Transceiver components

[0066] 20 Fieldbus Communication Processors

[0067] 21 Voting Units

[0068] 22 Execution Components (Process Automation Execution Engine)

Claims

1. A process control system (10), comprising: at least one module terminal unit (11); at least one adapter module (12) arranged on the module terminal unit (11) and configured to communicate with a field device; as well as at least one controller module (13) arranged on the module terminal unit (11) and configured to process data from the adapter module (12); The adapter module (12) and the controller module (13) are connected to each other via a peer-to-peer connection (14), in particular via a module terminal unit (11).

2. The process control system of claim 1, wherein the controller module (13) is connected to a plurality of adapter modules (12) via peer-to-peer connections.

3. The process control system according to claim 1 or 2, wherein the adapter module (12) is connected to a plurality of controller modules (13) via peer-to-peer connections (14).

4. The process control system of claim 3, wherein at least one controller module (13) of the plurality of controller modules (13) is a redundant controller module (13).

5. The process control system according to any of the preceding claims, wherein the peer-to-peer connection (14) comprises a plurality of peer-to-peer signal channels, in particular bidirectional channels and / or unidirectional channels.

6. The process control system according to any of the preceding claims, wherein the adapter module (12) comprises a selector element (15) configured to select one peer connection of a plurality of peer connections (14).

7. The process control system according to any of the preceding claims, wherein the adapter module (12) comprises a configuration element (16) configured to control the selector element (15).

8. The process control system according to claim 6 or 7, wherein the controller module (13) comprises a configuration unit (17), wherein the configuration unit (17) is configured to communicate with a configuration element (16) of the adapter module (12).

9. A process control system according to any one of claims 6 to 8, wherein the selector element (15) of the adapter module (12) includes a peer connection (14) to the selector element (15) of the controller module (13), and the configuration element (16) of the adapter module (12) includes a service bus connection (18) to the configuration unit (17) of the controller module (13).

10. The process control system according to any of the preceding claims, wherein the adapter module (12) and the controller module (13) are separate hardware components.

11. A process control system according to any one of the preceding claims, wherein the peer connection (14) is achieved via wiring in the module terminal unit (11).

12. The process control system of claim 11, wherein the wiring of the peer connection (14) in the module terminal unit (11) is passive wiring.

13. The process control system according to any of the preceding claims, wherein the adapter module (12) comprises a galvanic insulation between the signal of the selector element (15) and a fieldbus signal.

14. The process control system according to any of the preceding claims, wherein the adapter module (12) comprises at least one transceiver element (19) for one or more fieldbuses.

15. A process control system according to any one of the preceding claims, wherein the controller module (13) comprises a fieldbus communications processor (20) for one or more fieldbuses.

16. A process control system according to any of the preceding claims, wherein the controller module (13) comprises a voting unit (21) connected to the selector element (15) and the fieldbus communication processor (20).

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