An integral field device, an integral distributed controller and a method for integral controlling of an industrial process

Abstract

A method for integral controlling of an industrial process can include steps of: (a) dedicating said distributed functional tasks, wherein are each uninterrupted in running thereof by others, each of said dedicated functional tasks is defined by a location label in space of the industrial process; (b) providing a digital interface for each of the dedicated functional tasks to digitally control therefor; (c) providing the corresponding control subprograms to control the dedicated functional tasks via the digital interfaces thereof, respectively, wherein each of the corresponding control subprograms is provided to be uninterrupted by other of the corresponding control subprograms in executing thereof; (d) compiling the corresponding control subprograms in a control program, wherein each of the corresponding control subprograms is defined by a corresponding program label, whereby the corresponding control subprograms are intercommunicated one other for running the control program; (e) providing a subprogram communicating interface for each of said corresponding control subprograms, whereby said corresponding control subprograms are communicativeable; (f) providing a controlling algorithm, whereby said corresponding control subprograms are intercommunicated one other via said control program running environment for running said control program, wherein said corresponding control subprograms are intercommunicated one other by applying said program labels thereof; (g) integrating at least the corresponding digital interface, corresponding control subprogram and subprogram communicating interface defining the corresponding dedicating functional task to configure a corresponding integral field device, IFD, provided with an embedded software executing facilities, whereby each of steps (a) - (g) is accomplished for controlling said corresponding dedicated functional task; (h) embedding IFD controlling interface in said corresponding IFD, whereby each of steps (a) - (g) is controlled; (i) locating said corresponding IFD in the location of said corresponding dedicated functional task to be controlled therefor; (j) integrating a corresponding plurality of said corresponding IFDs, where are each located in the location of the corresponding dedicated functional task, to configure a single integral distributed controller, IDC, wherein the IFD controlling interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure the distributed software runtime operating environment, the subprogram communicating interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure a control program runtime environment, for said integral controlling of said industrial process, respectively; (k) configuring said IFD controlling interface embedded into each of said corresponding IFDs of said IDC to control and acquire data of each of said corresponding IFDs and dedicated functional tasks to be controlled thereby, wherein said data is provided via said software runtime operating environment for controlling other corresponding IFDs and dedicated functional tasks to be controlled thereby, in said IDC for said integral controlling of the industrial process, respectively; (1) providing Integrated Development Environment for developing each of steps (a) - (k). An integral field device, IFD, integrates at least at least the corresponding digital interface, corresponding control subprogram and subprogram communicating interface defining the corresponding dedicating functional task, and IFD controlling interface, for controlling the IFD and corresponding dedicating functional task in its location. An integral distributed controller, IDC, includes at least a plurality of IFD devices neighborly connected one other for configuring a software runtime operating environment and a control program runtime environment providing to accomplish the integral controlling of the industrial process.

Description

[0001] An Integral Field Device, Integral Distributed Controller and A Method for Integral Controlling of an Industrial Process

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to industrial control systems, ICS, in particular to distributed control systems, DCS, for controlling an industrial process using the field devices for controlling the distributed functional tasks integrated in the industrial process.

[0004] BACKGROUND OF THE INVENTION

[0005] Generally, Industrial Control relates to controlling of an industrial process, which represents a plurality of the distributed functional tasks are each associated with the corresponding field device remote-connected to industrial controller, PLC, which executes a control program, which represents a plurality of the control subprograms are each associated with the corresponding distributed functional task to be remote-controlled via the corresponding field device, respectively.

[0006] In the last decades, Industrial Control Systems (ICS) evolved towards distributed control systems (DCS) and / or distributed software -defined systems with smart and / or Al control facilities declaring high level of the control capability and security with data communications of Internet-of-Things, loT, Industrial Internet of Things, IIoT.

[0007] US 9,912,737 B2 discloses a modular and interoperable distributed control system for controlling an industrial process using a plurality of distributed control nodes interconnecting via Layer 3 switched Ethernet IP network.

[0008] WO 2019 / 099111 A 1 discloses a distributed software-defined industrial system having flexible operative features thereof. Guide to Industrial Control Systems (ICS) Security, NIST Special Publication 800-82, Revision 2, Sept. 28, 2023,

[0009]

[0010] which provides guidance on how to secure Industrial Control Systems (ICS), including Supervisory Control and Data Acquisition (SCADA) systems, Distributed Control Systems (DCS), and other control system configurations such as Programmable Logic Controllers (PLC), while addressing their unique performance, reliability, and safety requirements.

[0011] W.Z. Khan et al, Recent advances, enabling technologies and open challenges, Computers and Electrical Engineering 81 (2020), 106522) discloses a vision of loT in the industrial sector by automating smart objects for sensing, collecting, processing and communicating the real-time events in industrial systems.

[0012] Even so, the accidents with heavy consequences continue to occur, because, obviously, the data control architecture and general skeleton for controlling of the industrial processes of various industrial objects remains unchanged.

[0013] First, each field device remains to be primitive with in / out - or of digital Boolean logic or of analog 4-20 ma, which are connected to I / O of the distanced Programmable Logic Controllers (PLC) of DCS controlling therefor via complicated wires / cables infrastructure. Because of the practical limitedness of a number of I / O ports in each PLC, a number of PLCs arranged in PLCs network including the coordinating computers and computer centers for controlling a big manufacturing process.

[0014] Correctly, the field device, in existing industrial control concept, defines “a functional components” which is mounted in the functional point location of the industrial process, respectively, for measuring or manipulating it.

[0015] Each existing field device represents a functional module executing the functional point (temperature, pressure, flow etc.), and includes a functional circuit, setting circuit, and one-channel output. For example, a temperature sensing field device represents a functional module including a temperature measuring circuit, where a resistance (or micro voltage) value proportional to the measuring temperature is converted to the operating voltage; a setting circuit of the controlling comparator configured for comparing the operating voltage with the predetermined set point voltage; the controlling comparator defines One-channel output of Boolean logic type (“opened / closed,” “on / off or "1 / 0")

[0016] (

[0017]

[0018] Historically, Boolean logic has defined the operating architecture of PLC (and vice versa), in which the “field devices” are a source of the interruptions of the industrial process control program running in PLC, which scans and interprets each "in,” for initiating the interruptions to execute the corresponding subprogram of the control program related to the corresponding interruption, in turn, the subprograms initiate the PLC’s output signals. PLC executes the control subprograms at a queue of random interruptions arriving from sensors.

[0019] Referring to Ashby, W. R. (1956), “An Introduction to Cybernetics, Chs.10, 11, 12, 1st Ed. New York, NY: John Wiley and Sons.” (hereafter, Cybernetics) the optimal control, in particular, industrial control relates to the direct control described by cybernetic control expression:

[0020] D — > R— > T (1)

[0021] Herein, the regulator R is associated with control program where it receives information (disturbance D) from e.g. sensors, solves it, and sends back the updated acts, T, to e.g. actuators.

[0022] Referring to well-known Queuing Theory and there Erlang formulas, the queue of the executed subprograms could be blocked i.e. in any way the control program running and the industrial control can be blocked and stopped (during second, minute, hours or years), and Erlang formulas probability confirms this. In safeness reasons, any interruptions of the control program running are not acceptable; the control of the industrial process should be pause-less. Despite on declaring real-time DCS control, really it is only “buzzword’ (no more).

[0023] Therefore, the existing industrial DCS control, where the control program operates the information and action related to the field devices through ultra-complicated PLCs system, has the features to be the “dis-integrating control.”

[0024]

[0025] In prior art, instead to solve the dis-integration and increase the DCS informative controllability, loT and IIoT are proposed to be implemented in DCS and to become such uncontested feature operating via the mentioned Network Layer 3.

[0026] In safeness and operational reasons, any Internet technologies are the problem for industrial controlling.

[0027] First, the servicing data flow, (e.g. configuring procedures, spanning tree and routing loops control, links establishing, on-demand access etc.) has a stochastic nature, and the application data flow of the distributed control program execution has a pre-determined nature, which share one stack / interface such as software TCP / IP / MAC stack and, farther the physical interface e.g. Industrial Ethernet. Obviously the stochastic data flow is at-risk for data packets flow congestion causing traffic jams for both data flows, and herein the control program executed in manner of the packetized data flow via networking computing systems conceptually might be interrupted at-risk for accident, as well. The Queue theory is the fundamental basis of computer networking - Internet, which is ignored by loT and IIoT developers (herein Internet and Industrial Internet are interchangeable).

[0028] Second, each addressing system, in particular the considered TCP / IP / MAC stack / interface transforms each computing node to be autonomous regarding other ones, where said autonomy relates to a feature of “black box.” In other words the loT or IIoT systems are the "black boxes" systems requiring ultra-complex software runtime for industrial control, where such feature as entropy, known as Internet entropy, reflecting measure of the network disorder is. Bugs, cyberattacks, and human errors are problems for even the most sophisticated and intelligence of Internet DCS, including Al. It is well-known the entropy is not a deviation of some that may be fixed, the entropy is a property of informative communications related to autonomy, which cannot conceptually be arranged in well-regulated control system. It becomes obvious, even declining internet entropy may prove even harder or impossible at all, across Industrial Internet.

[0029] In accordance with previously mentioned, there are certainly required the integral industrial control systems; which are built on the field devices level operating with great mass of information, where any interruptions and “disintegrations” of the control program are conceptually excluded. SUMMARY OF THE INVENTION

[0030] The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description and claims hereof, as well as from the appended drawing that follows. A one object of the invention discloses a method for integral controlling of an industrial process, comprising at least the following steps: (a) dedicating said distributed functional tasks, wherein are each uninterrupted in running thereof by others, each of said dedicated functional tasks is defined by a location label in space of the industrial process; (b) providing a digital interface for each of the dedicated functional tasks to digitally control therefor; (c) providing the corresponding control subprograms to control the dedicated functional tasks via the digital interfaces thereof, respectively, wherein each of the corresponding control subprograms is provided to be uninterrupted by other of the corresponding control subprograms in executing thereof; (d) compiling the corresponding control subprograms in a control program, wherein each of the corresponding control subprograms is defined by a corresponding program label, whereby the corresponding control subprograms are intercommunicated one other for running the control program; (e) providing a subprogram communicating interface for each of said corresponding control subprograms, whereby said corresponding control subprograms are communicativeable; (f) providing a controlling algorithm, whereby said corresponding control subprograms are intercommunicated one other via said control program running environment for running said control program, wherein said corresponding control subprograms are intercommunicated one other by applying said program labels thereof; (g) integrating at least the corresponding digital interface, corresponding control subprogram and subprogram communicating interface defining the corresponding dedicating functional task to configure a corresponding integral field device, IFD, provided with an embedded software executing facilities, whereby each of steps (a) - (g) is accomplished for controlling said corresponding dedicated functional task; (h) embedding IFD controlling interface in said corresponding IFD, whereby each of steps (a) - (g) is controlled; (i) locating said corresponding IFD in the location of said corresponding dedicated functional task to be controlled therefor; (j) integrating a corresponding plurality of said corresponding IFDs, where are each located in the location of the corresponding dedicated functional task, to configure a single integral distributed controller, IDC, wherein the IFD controlling interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure the distributed software runtime operating environment, the subprogram communicating interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure a control program runtime environment, for said integral controlling of said industrial process, respectively; (k) configuring said IFD controlling interface embedded into each of said corresponding IFDs of said IDC to control and acquire data of each of said corresponding IFDs and dedicated functional tasks to be controlled thereby, wherein said data is provided via said software runtime operating environment for controlling other corresponding IFDs and dedicated functional tasks to be controlled thereby, in said IDC for said integral controlling of the industrial process, respectively; (1) providing Integrated Development Environment for developing each of steps (a) - (k).

[0031] Another object of the invention discloses an integral field device, IFD, providing to accomplish the integral controlling of the dedicated functional task of the industrial process, IFD device includes at least: (a) an industrial functional task controlling module (p-module), including a functional microcontroller (f-microcontroller), a subprogram executing microcontroller (p-microcontroller) and a subprogram communicating microcontroller (p-router), therein p-microcontroller communicatively coupled with said f-microcontroller in local controlling aspects, and communicatively coupled with p-router in integral controlling aspects, respectively, f-microcontroller includes at least the embedded corresponding software runtime environment configured to provide a digital interface to said dedicated functional task for controlling thereof in said local controlling aspects, p-microcontroller includes at least the embedded corresponding software runtime environment configured for executing the installed therein corresponding control subprogram controlling said dedicated functional task via said f-microcontroller digital interface in local controlling aspects, and via said p-router in integral controlling aspects, respectively, said corresponding control subprogram is defined by the corresponding communicative label (p-label), p-router includes at least the embedded corresponding software runtime environment configured to provide a data packets switching circuit (p-switch) with one or more data communicating interfaces of the physical layer type (p-interface), whereby said corresponding control subprogram intercommunicates by applying said p-label thereof; (b) an operational module (d-module), includes a directives processing microcontroller (d-microcontroller), and directives communicating microcontroller (d-router), d-microcontroller includes at least the embedded corresponding software runtime environment configured for processing the directives of data acquire and control each microcontroller of said p-d modules in response to the corresponding inbound directive instructions and to send outbound directive instructions, in said local and integral controlling aspects, said d-microcontroller is defined by the corresponding location label (d-label), said d-router includes at least the embedded corresponding software runtime environment configured to provide a data packets switching circuit (d-switch) with one or more data communicating interfaces of the physical layer type (d-interface), whereby said corresponding inbound directive instructions and outbound directive instructions are communicated by applying said d-label; (c) an interior control and data acquisition bus (IFD-bus), said f-microcontroller, p-microcontroller, d-microcontroller, p-router and d-router are each provided with selectable in-circuit control and data acquisition interface to be coupled with said IFD-bus to be selectively controllable and data acquirable.

[0032] Another object of the invention discloses an integral distributed controller, IDC, providing to accomplish the integral controlling of the industrial process, said IDC controller has at least an software runtime operating environment and the control program runtime environment, said IDC controller includes a plurality of the distributed integral field devices, IFD, distributed for integral controlling an industrial process, each pair of the neighboring IFD devices of said plurality of the distributed IFD devices are connected one other via at least one d-interface of said d-switch, of said d-routers respectively, whereby the d-microcontrollers of said plurality of the distributed IFD devices are communicable with each other providing said software runtime operating environment (d-environment), said d-labels of said IFD devices are applied for intercommunicating said directive type instructions, respectively, each pair of said neighboring IFD devices of said plurality of the distributed IFD devices are connected one other via at least one p-interface of said p-switch, of said p-routers respectively, whereby said p-microcontrollers of said plurality of the distributed IFD devices are communicable with each other providing said control program runtime environment (p-environment), wherein said p-labels of the corresponding control subprograms are intercommunicated, respectively.

[0033] Next object of the invention discloses a method of configuring IDC controller, the method includes at least the operations of: (a) providing a plurality of IFD devices in accordance to the functional tasks of the industrial process; (b) generating d-labels identifying each IFD device in accordance to locations of the functional tasks in the industrial process; (c) generating a routing data by compiling the sequences of the linking d-labels, whereby the d-labeled IFD devices link with each other in said plurality of IFD devices; (d) initializing each IFD device of the plurality of IFD devices for integrating in the IDC controller, the initializing further including: (i) loading an d-label into a d-microcontroller; (ii) installing the routing data of d-labels into a d-router; (iii) adopting the d-labels for communicating the IFD devices with each other; (e) mounting each IFD device of the plurality of IFD devices in the functional tasks locations; (f) applying the d-labels to head the data packets for delivering the data packets to the dedicated IFD devices via the d-environment in accordance to said routing data; (g) checking the physical correspondence of mounted IFD devices by the delivering the data packets to the IFD devices respectively; (h) configuring the IFD devices to implement one or more distributed control strategies for integral controlling of the industrial process;

[0034] A further object of the invention is to provide the aforesaid method wherein the operation (c) further includes the operations of providing alternative routing data by the compiling d-labels; A further object of the invention is to provide the aforesaid method further including the operations of integrating at least two neighboring IDC controllers: (a) selecting pairs of the neighboring IDC controllers to be integrated in neighboring spatial areas; (b) selecting pairs of neighboring IFD devices each belonging to different neighboring IDC controllers in the pairs of neighboring IDC controllers; (c) integrating the neighboring IFD devices within said selected pairs of neighboring IFD devices within selecting pairs of neighboring IDC controllers, respectively;

[0035] Next object of the invention discloses a method of compiling a control program for integral controlling of the industrial process by at least one aforesaid IDC controller, the method includes at least the operations of: (a) defining the IFD devices to execute the control subprograms to be compiled in the control program, in the at least one IDC controller; (b) developing a control algorithm of the control program whereby to implement one or more distributed control strategies for integral controlling of the industrial process, in which the control subprograms to be compiled interoperate with each other; (c) assigning the program labels (p-label) for each of the control subprograms in accordance to the control algorithm of the control program; (d) configuring said p-labels in accordance with d-labels of said IFD devices; (e) generating a routing data by compiling the sequences of the linking p -labels, whereby p-labeled control subprograms interoperate with each other in accordance to said control algorithm of said control program, respectively; (f) installing the p-labels of the control subprograms into p-microcontrollers of the IFD devices via the d-environment of the at least one IDC controller; (g) installing the routing data into p-routers of the IFD devices via the d-environment of the at least one IDC controller; (h) providing to run the control program by the IFD devices executing the control subprograms in accordance with the control algorithm of the control program in the at least one IDC controller;

[0036] A further object of the invention is to provide aforesaid method, in which operation (e) further including an operation of providing alternative routing data by the compiling the p-labels; A further object of the invention is to provide aforesaid method, in which operation (h) includes the execution of the previous and next control subprograms executed by the executing IFD devices consecutively, wherein the dedicated p-label of the previous control subprogram is sent, via p-environment of the at least one IDC controller, in response to ending thereof for executing the next control subprogram executed in accordance to the control algorithm;

[0037] BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Fig. 1 illustrates a general schematic diagram of an integral field device, IFD.

[0039] Fig. 2 illustrates a general schematic diagram of an industrial communication interface for connecting the neighboring IFD devices.

[0040] Fig. 3 illustrates a general schematic diagram of an integral distributed controller, IDC.

[0041] Figs 4a and 4b illustrate a schematic diagram for “stitching” a number of the IDC controllers nested in single enclosing IDC controller.

[0042] Fig 5 illustrates an imagination of the industrial integral controlling in accordance with the invention.

[0043] DETAILED DESCRIPTION OF THE INVENTION The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description that follows, and sets forth the best modes contemplated by the inventor of carrying out this invention. The disclosed subject matter includes an integral field device, IFD, for controlling a single functional task in the location thereof, and an integral distributed controller, IDC for controlling the distributed single functional tasks integrated in industrial process.

[0044] As far as reference is made to specific procedural or structural components, this is to be considered as example for the underlying functionality, where the procedural or structural components are clearly exchangeable as long as the same functionality is achieved. The functionality of the industrial control of the distributed single functional tasks integrated in industrial process in real time according to the present invention is manifold. Contrary to the prior art it supports a flexible real time process control, where Al techniques may be used, although in the present invention it will be explained using generic terminology to avoid restriction of the scope of protection.

[0045] It is further understood that one possessing ordinary skill in the art, in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending upon specific design and other needs. It should be noted that the terms "comprises, “comprising," “include”, “including” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a method, system or device that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such, method, device, system.

[0046] It should be noted that such term as "digital twin" in the present invention is not an abstraction but it is related to one of the kinds of a digital interfaces for real-time controlling of the physical object regarding overall controlling e.g. via machine-vision cameras, and it is intended to avoid restriction of the scope of protection.

[0047] The terms “providing” or "configuring" are to be construed broadly. The specific meaning of the above terms in the present invention can be understood according to specific situations by those skilled in the art.

[0048] 1. Overview of the integral controlling The main idea of the present invention regarding to implement optimal controlling of the industrial process is to apply basics of Cybernetics and system integration in best synergy. Generally, the integral controlling relates to “System integration, that is defined in engineering is the process of bringing together the components of subsystems into one, so that the system is able to deliver the overarching functionality and ensuring that the subsystems function together as a system. In information technology the system integration is the process of linking together different computing systems and software applications physically or functionally, to act as a coordinated whole...” (https: / / en.wikipedia.org / wiki / System integration and references therein).

[0049] In accordance to Cybernetics (Ch.11, in particular 11 / 6), the optimal control, particularly, industrial process control is possible by adopting the commonly known Law of Requisite Variety, which originally states: “....only variety in regulator R can force down the variety due to disturbances D; variety can destroy variety”...

[0050] However, Law of Requisite Variety also says that R’s capacity as a regulator cannot exceed R’s capacity as a channel of communication. In our case, a control program is the regulator for executing a control of the industrial process, which includes a plurality of the distributed functional tasks are each controlled by a corresponding control subprogram to be compiled in the control program.

[0051] Hence, each control subprogram of whole control program must to be executed separately and independently one other, but in integral manner in accordance to the control program running rules, then the maximum of said R’s capacity will be provided, respectively.

[0052] On the other side to be optimal the regulator R must adopt and adapt the basics of commonly known “Good Regulator theorem,” which is central to Cybernetics that defines an optimal controlling regulator, it originally states as "every good regulator of a system must be a model of that system.”

[0053] Therefore, if the regulator R of the industrial process is the control program, then and the architecture of the industrial control system, where the control program is executed, has to be like a programming language architecture.

[0054] In accordance to the invention Assembler language architecture (hereafter, Assembler) and rules are adopted for building the architecture of the optimal regulator.

[0055] http: / / www.rihcoding.com / ayr-asm-structure-of-an-asm-program.php; https: / / ww1.microchip.com / downloads / en / devicedoc / 33014g.pdf.

[0056] An architecture and rules of other programming languages, as well as languages operating with Al, is in scope of the present invention.

[0057] It is commonly known, Assembler, e.g. in given control applications, defines the system integration of the controlled process and control it program, where

[0058] the first is a plurality of the functional tasks are each distributed in space of the controlled process and interacted in accordance to the specific algorithm, i.e. each functional task can be defined by the coordinates in the space of the industrial process, in which it is marked by e.g d-label directing to other functional features, e.g. digital interface there-to-from, as well; the second is a sequence of the control subprograms are each controlling the corresponding functional task (via the digital interface) and intercommunicating in accordance to the program running algorithm reflecting the specific algorithm of the controlled industrial process, where each control subprogram is defined by the program p-label.

[0059] Therefore, the control program becomes such virtual system integrator of the p-d-labeled components requiring to be operated in some microcontroller, having commonly well-known architecture.

[0060] The programmer writing the control program, identify and mark the control subprograms via the program labels (p-labels) e.g. "label, i" (where a sign "i" relates to the certain subprogram). Then, programmer uses the operating instructions, which are converted in microcontroller machine code, which is programmed into, causing to perform the interior or peripheral I / O operations.

[0061] There are the program directives, i.e. directive-type instructions, which are visible in program listing, and invisible in machine code; the directive -type instructions define the specific microcontroller configuration (peripheral I / O, synch mode, etc.) and various setting of the executed program e.g. data byte / word length, data massive size etc.

[0062] The microcontroller has a certain embedded corresponding software operating environment and program runtime environment, which is configurable via directive-type instructions and operable via the operating instructions, and which include a processor unit for executing the operating instructions, program memory and data memory, which are used for storing the operating instructions and data further to be executed, respectively. The program and data memory has the certain addressing order e.g. memory address, pages, blocks, banks etc. forming the microcontroller addressing space, which can be automatically or manually configured and pointed by the specific directive-type instructions e.g. whereto to write and wherefrom to read the operating instructions and / or data.

[0063] The processor unit of each microcontroller has a "program counter" (special register of the processor that contains a counter defining a memory address of the next operating instruction to be executed), which when read by the processor, causes the (micro-)-controller to perform the corresponding peripheral or internal operations.

[0064] If the processor reads an instruction e.g. “goto (label i)”, then the address value of the program counter jumps to the address value of the subprogram defined by directive “label i” for further executing. In other words, the subprograms are communicated with each other via switching the address value by the program counter.

[0065] Thus, the subprograms are distributed (manually or automatically) in the certain locations of the addressable space of the microcontroller memory pointed by "label i" and accessible via the program counter.

[0066] Obviously, we can state Assembler provides the integral controlling of the controlled functional tasks reflecting the integral controlling of the industrial process.

[0067] In accordance to the present invention the industrial process is divided on dedicated functional tasks (in simple manner sensors and actuators) are each defined by its functional features and location in the space of the industrial process marked by d-label.

[0068] A corresponding control subprogram is specifically developed for controlling each dedicated functional task, which becomes the controlled object and is marked by program p-label. A digital interface is provided for dedicated functional task to be machine -readable object synchronized with real physical task and where the corresponding control subprogram operated by the corresponding control subprogram.

[0069] The digital interface performed in manner of the I / O interface, digital twin and / or Al component is in scope of the present invention.

[0070] For controlling and data acquiring as the dedicated functional tasks as the corresponding control subprograms in local and integral controlling aspects Assembler-type directives are applied. In technical manner the digital interface, the corresponding subprogram and Assembler-type directives are presented by the corresponding functional, program and directives operating f-p-d-microcontrollers, in which these are installed and executed, respectively.

[0071] The f-p-d-microcontrollers are integrally configured in physical integral field device, IFD device, which can be defined via p-label (“label i.”) of the control subprogram and via absolute and / or relative coordinates of the dedicated functional task location in the space of the industrial process, defined as d-label. In this way, the program component “p-label " acquires the physical processing location d-label; and each IFD device can be interpreted as a processing and memory unit, which is located in the addressable processing and memory space of an integral plurality of the IFD devices distributed in industrial process.

[0072] In accordance to the present invention, each IFD device is equipped by the p-router and d-router are each equipped by the packetized data communicating switch with the physical data transceiving interface.

[0073] Therefore, each IFD device is provided with two separated and independently arranged data communications paths, whereby the neighboring IFD devices are connected one to other to configure the data communicating software runtime operating environment and data communicating control program runtime environment, where in opposite to machine-code Assembler program listing components are applied: a first intercommunicates p-labels for the control program running, a second intercommunicates the data packets with d-label header and directives body.

[0074] This Assembler data communication technique operates in distance, and it is implemented instead the commonly known “program counter”.

[0075] Then, a plurality of IFD devices are processing and memory units, which are integrated in the greater (theoretically infinite) physically distributed, but single computing structure of integral distributed controller, IDC, which is deployed in space, where the operators (human) controlling the industrial process locate and working inside this controller.

[0076] IDC is formed by the distributed software operating runtime environment and control program runtime environment of the included therein IFDs.

[0077] For imagination, each IFD device can be interpreted as human, which performs certain functional task e.g. on conveyor, and which simultaneously has ability to directivity speak with other humans, i.e. each IFD device acquires a directive-type instructions language for implementing artificial intelligence of the integral controlling, IFD Al language.

[0078] The directive-type instructions (the subprogram labels as well) become communicatively visible. These directive-type instructions are embedded in a list of IFD device controlling directives providing to control the IFD device components. Although the directive -type instructions can be same in syntax aspects, these can be different in semantic aspects, and these can be variously implemented in technical aspects of the IFD device function.

[0079] It is understandably, each IDC controller including IFD devices is provided with Integrated Development Environment (IDE-IDC), which in software development aspects include the developing applications including, in turn, configuring and computing applications, and communicative applications, including, in turn, linking, programming and debugging applications having analogues in software development field e.g.

[0080] https: / / www.microchip.com / en-us / tools-resources / develop / mplab-x-ide.

[0081] Therefore, the Law of Requisite Variety and Good Regulator Theorem are implemented with system integration techniques for optimal non-blocking integral controlling of the industrial process.

[0082] Reference will now be made in detail to the preferred exemplary embodiments of the invention objects in industrial applicability aspects, exemplary embodiment of which is illustrated in the accompanying drawings.

[0083] 2. An integral field device, IFD

[0084] In accordance with an exemplary and non-limiting embodiment, with reference to Fig. 1, an integral field device, IFD, 100 architecture is disclosed.

[0085] IFD device lOO.i is operatively divided on two independent, but interoperable, modules an industrial task controlling module (p-module), and operational module (d-module).

[0086] The p-module includes a functional microcontroller (f-microcontroller) 110 associated with functional task 2O.i of the industrial process; a subprogram executing microcontroller (p-microcontroller) 120 and a subprogram communicating microcontroller (p-router) 130.

[0087] The d-module includes a directives processing microcontroller (d-microcontroller) 140 and directives communicating microcontroller (d-router) 150. The IFD device has and an interior control and data acquisition bus (IFD-bus) 160 therewith all of said microcontrollers are coupled to be accessible for controlling and data acquisition. The IFD device has an external data communications interface 170 with two separate data communications parts, where one relates to p-module and another relates to d-module, whereby IFD device is communicable in integral controlling aspects, the data communications interface 170 in more details is shown in Fig. 2.

[0088] The component called as “microcontroller” may be represented as chip, integral circuit, a complex circuit, and System-on-chip, or system-in-package.

[0089] 2.1 The functional microcontroller 110 (f-microcontroller) is a controllable component which performs the real-value functional operations for digitizing the dedicated functional task 2O.i into machine-readable digital interface 111 imitating the dedicated functional task in real-time mode.

[0090] For technical clarify, a digital interface is a dynamic digital replica of the dedicated functional task reflecting strong intersection between the physical and virtual worlds, where simple converting of the real value to machine-readable data is performed e.g.

[0091] T (⁰C) ~ T (⁰C) x 1 (bytes / ⁰C) ~ T (bytes);

[0092] V ( m3) ~ V ( m3) x 1 (bytes / m3) ~ V (bytes), https: / / www.allaboutcircuits.com / news / digital-twin-technology-and-its-impact-on-manufacturing-and-business /

[0093] The f-microcontroller 110 includes the digitizing facilities 111.20.i, and embedded corresponding software environment configured to provide the digital interface 111 to the dedicated functional task for controlling thereof in the local controlling aspects. The digitizing facilities 111.20.i represent e.g. analog-to-digital convertors, ADC, or digital-to-analog convertors DAC. The dedicated functional task may be represented in simple manner as sensor or actuator

[0094] The f-microcontroller 110 and p-microcontroller 120 are physically interconnect via mutual interface 121.111 (e.g. UART) associated with the digital interface 111 in local controlling aspects.

[0095] The f-microcontroller includes selectable in-circuit control and data acquisition interface 112 coupled with the IFD-bus 160. The parameters of the digital interface 111 for controlling the dedicated functional task e.g. sampling rate, a range, and behavior over time etc. are changeable via interface 112, which is integrated with the microcontroller-programming interface (https: / / www.microchip.com / en-us / tools-resources / develop / mplab-x-ide).

[0096] The microcontroller is mentioned as an example of the most practical aspects; others solutions of the f-microcontroller to provide the digital interface based on various logic devices are in the scope of the present invention, e.g.

[0097] https: / / en.wikipedia.org / wiki / Programmable logic device

[0098] 2.2 A subprogram executing microcontroller (p-microcontroller) 120 p-microcontroller includes the embedded corresponding software environment 121 configured for executing the installed therein corresponding control subprogram 200.i controlling the dedicated functional task 2O.i via f-microcontroller digital interface 111 in local controlling aspects, and via p-router 130 in integral controlling aspects, respectively; for that p-microcontroller communicatively coupled via communicating interface 131.121 (e.g. UART) with p-router 130..

[0099] As well as p-microcontroller includes a selectable in-circuit control and data acquisition interface 122 coupled with the IFD-bus 160, whereby p-microcontroller 120 and the control subprogram 200.i are accessible for supervising, configuring and setting.

[0100] In some industrial applications the selectable in-circuit control and data acquisition interface 122 is integrated with e.g. in-circuit serial programming interface of p-microcontroller

[0101]

[0102] For industrial applicability, the dedicated functional task digital interface 111 and the control subprogram 200.i for controlling therefor are embedded in IFD device by IFD manufacturers. For integral controlling of the industrial process, the control subprogram 200.i is programmatically assigned by p-label (“label i”) in accordance with the control algorithm of the control program 200. The control subprogram 200.i is continuously executed in p-microcontroller for controlling the dedicated functional task 2O.i via the digital interface 111; and the control subprogram 200.i is continuously communicated with other control subprograms of the control program by sending the corresponding p-labels via p-router. Thus, the functional elements defining the technological parameters of the industrial process are minimized in the dedicated functional task, which is further associated with digital interface, which is further controlled by the control subprogram executed only and only in the location of the dedicated functional task, and which is interoperated with other control subprogram analogously command "goto". In this technique, the control algorithm of the control program allows excluding any interruptions of the control program running, and “blocking” the integral controlling the industrial process at all.

[0103] The various embodiments of the p-microcontroller 120, the interface 121.111, the control and data acquisition interface 122, are in scope of the invention, respectively.

[0104] 2.3 A subprogram communicating microcontroller, (p-router) 130 is provided with a data packets switching circuit (p-switch) 131 with one or more data communicating interfaces of the data communications physical layer (p-interface) 171, by which the neighboring IFD devices are connected one other in structure of the integral distributed controller, IDC 10, disclosed below and shown in Fig. 3, the control program runtime environment (p-environment) of IDC 10 is formed.

[0105] As well as p-router 130 includes a selectable in-circuit control and data acquisition interface 132 coupled with the IFD-bus 160, whereby p-router 130 is accessible for configuring and setting the routing data.

[0106] Disclosed above p-microcontroller 120 includes a data communications interface 131.121 to be communicatively coupled with the p-switch 131, whereby the control subprogram 200.i executed in p-microcontroller are integrated in the control program 200 of the integral controlling of the industrial process. Simultaneously, p-router provides the link-through (“transparent”) communications for p-labels in the control program running aspects.

[0107] In the programming aspects p-router 130 could be interpreted as “program counter” executing the communicative instruction “goto label i.” Such architecture allows to sequentially run the control program without any interruptions.

[0108] The data packets headed by p-labels for further transferring does not out of skills of the data communications practices, and such data communications are friendly compatible with mentioned programming practices.

[0109] For technical clarify, p-switch 131 represents a data packets switch, which is embodied as switchable non-blocking data communications matrix (not shown) of physical layer operable via communications interfaces 170 with one or more switchable directions (in Fig. 1 is shown one direction, signed as 171, p-interface). A full-duplex industrial interface EIA-422, signed as 171.1, 171.2, 171.3, and 171.4 and shown in Fig. 2, is more preferably for industrial applicability

[0110]

[0111] The EIA-422 industrial standard is mentioned as an example for implementing the physical layer https: / / en.wikipedia.org / wiki / Physical_layer. The various techniques for implementing p-router, p-switch, and p-interface are in scope of the present invention.

[0112] 2.4 An operational module (d-module) 140 includes a directives processing microcontroller (d-microcontroller) 141, and directives communicating microcontroller (d-router) 150 including selectable in-circuit control and data acquisition interface 152 coupled with said IFD-bus 160.

[0113] The d-microcontroller includes an operational interface 142 coupled with IFD-bus 160, and an embedded corresponding software environment 300 configured for processing the directives of data acquire and control each microcontroller of said p-d modules in response to the corresponding inbound directive-type instructions and to send outbound directive-type instructions, in local and integral control aspects of said industrial process, the d-microcontroller communicatively coupled with said d-router via communicating interface 151.141 (e.g. UART).

[0114] The d-microcontroller technically translates the directive-type instructions into instructions, which the microcontrollers of d-p modules are able to “understand” and process.

[0115]

[0116] The directive-type instructions are such IFD devices language for "speaking" with each other in the distributed integral controlling aspects.

[0117] EXAMPLE:

[0118] IFD device for measuring a fluid flowrate can send the directive-type instructions to IFD device operating the corresponding fluid valve to set the certain fluid throughput.

[0119] A various plurality of the directive-type instructions are developed and formed to be directives database or directives library, which are saved in d-module e.g. in memory of the d-microcontroller or specific flash-type bootloader / backup storage chip (not shown) hosting aforesaid directive library. According to the customary practice, the directive library of directive-type instructions is preinstalled by the manufacturers and updated in-situate.

[0120] The various implementations of the directives library and / or database are in scope of the present invention.

[0121] D-microcontroller 141 of each IFD lOO.i is identified via a d-label in order to be communicatively accessible; d-label is assigned in-situate before when mounted in the IDC 10 as described below.

[0122] 2.5 A directives communicating microcontroller, (d-router) 150 in provided with a data packets switching circuit (d-switch) 151 with one or more physical layer interfaces (d-interfaces) by which the neighboring IFD devices are connected one other in structure of the integral distributed controller, IDC 10, disclosed below and shown in Fig. 3.

[0123] As well as d-router 150 includes a selectable in-circuit control and data acquisition interface 152 coupled with IFD-bus 160, whereby d-router 150 is accessible for configuring and setting the routing tables.

[0124] Disclosed above d-microcontroller 141 includes a data communications interface 151.141 to be communicatively coupled with the d-switch 151. The IFD devices lOO.i are connected with each other via d-interfaces thereof; and so, the software runtime operating environment (d-environment) of IDC controller 10 is formed, where data packets of the directive-type instructions headed by d-labels are transmitted in accordance to the routing data of the d-router 150, which are stored and updated therefor, providing link -through (“transparent”) communications.

[0125] The data packets communications, headed by d-labels do not out of skills of the data communications practices, as well as such data communications are friendly compatible with the programming practices.

[0126] For technical clarify, d-switch 151 represents a data packets switch, which is embodied as switchable non-blocking data communications matrix (not shown) of physical layer operable via communications interface 170 with one or more switchable directions (in Fig. 1 is shown one direction, signed as 172, d-interface). A full-duplex industrial interface EIA-422, signed as 172.1, 172.2, 172.3, and 172.4and shown in Fig. 2, is more preferably for industrial applicability https: / / ru.wikipedia.org / wiki / EIA-422. The EIA-422 industrial standard is mentioned as an example for implementing the physical layer https: / / en.wikipedia.org / wiki / Physical_layer. The various techniques for implementing d-router, d-switch, and d-interface are in scope of the present invention.

[0127] In opposite to the known I0T / II0T concepts, each IFD device lOO.i has the physically separated communications “p and d paths” for arranging the separated software runtime operating environment (d-environment); and control program runtime environment (p-environment) with independent communicability and synchronization.

[0128] As well as the separated communicating paths apply the different d-p-labels for heading the transmitted data packets, which differ significantly from Internet models, but even so are compatible with the programming practices, e.g. known “opcode” of the microcontroller instructions

[0129]

[0130] 2.6 Each IFD device is provided with integral development kit (IDK-IFD) and software environment thereof operable by general-purpose computer, wherein IDK-IFD includes one or more operative applications and communicating applications, which when are executed by the general-purpose computer, cause the general-purpose computer to generate the directive-type instructions applied for processing by d-microcontroller of IFD device for controlling therefor. In practical aspects, the manufacturer of the IFD devices provides a list of the directive-type instructions related to control the IFD modules and to communicate there between.

[0131] For technical clarify, there are the certain directive-type instructions including the directivetype instructions for communicating IFD devices with each other in the distributed integral controlling aspects. Although the directive-type instructions can be same in syntax aspects, these can be different in semantic aspects, and these can be variously implemented in technical aspects.

[0132] 3 Integral Distributed Controller, IDC

[0133] Fig. 3 illustrate in simple manner a schematic diagram of the integral distributed controller (IDC controller) 10, which is formed by a plurality of IFD devices lOO.i distributed in accordance with the locations of the dedicated functional tasks integrated in the industrial process. Despite on IDC controller 10 represents the distributed control system it is actually interpreted as integral circuit with overall synchronization, (i.e. in accurate manner it represents such spaced-apart computer with d-operational system, and p-applications do not shown herein). In order to provide the overall single synchronization the various synchronizing techniques are used, which are in scope of the present invention, e.g. https: / / en.wikipedia.org / wiki / Synchronization_network, and references therein.

[0134] There d-and-p microcontrollers 121 and 141 of the neighboring IFD devices lOO.i are separately connected by the p-d routers 130 and 150 via p-d-switches 131 and 151 and physical layers 171 and 172, respectively, and in this technique the aforementioned control program runtime environment (p-environment) and software runtime operating environment (d-environment) of IDC controller are formed. Herein, the p-microcontrollers belonging to IFD devices lOO.i form an integral p-controller of the IFD controller 10, while the d-microcontrollers belonging to the IFD devices lOO.i also are operated as the integral d-controller of the IFD controller 10.

[0135] Fig.5 illustrates an imagination of the industrial process 20 integrated with IDC controller 10 for integral controlling. The control program 200 is compiled from the control subprograms {pl, p2, p3, p4, p5 } are each signed as 200.i and located in the corresponding p-microcontrollers. The IFD devices communicate via communications interface 170 of physical layer, shown as example in Fig. 2. The industrial process is controlled by an operator via Supervisory Control and Data Acquisition, SCADA system embedded in computer 11 acquiring data from each of IFDs.

[0136] In Fig. 2 is shown a power interface 173 for providing "across-the-board" power supply of the IDC controller 10.

[0137] The waterproof and / or flameproof Distributed Controller, IDC, where IFDs of the hermetic type connected via cable of type shown in Fig. 2, are in scope of the present invention.

[0138] IFD device architecture and IDC controller architecture are flexible and independent on any of third parts requirements in programming, configuring, and communicating and safeness aspects.

[0139] 4 Integral Development Environment of IDC controller IDC controller 10, shown in Fig. 3 is provided with integral development environment, IDE-IDC, integrated with at least one general -purpose computer 11.

[0140] To connect with d-environment and p-environment of IDC controller, the general-purpose computer is provided with p-router and d-router, disclosed above, for communicatively coupling therewith via e.g. communications bridge Ethernet-USB-RS422.

[0141] The general-purpose computer is provided with software environment executing the operational and developing applications of the IDE-IDC.

[0142] The operational applications interoperating with IFD devices of IDC controller are assigned with specific ports# (referring to TCP / IP OSI model) that has to be allocated to programmatically create a communication sockets of (“port# & d-label”) for communicating with d-microcontrollers of IFD devices to be mounted in IDC controller respectively. Then, each IFD device of the plurality of the IFD devices mounted in IDC controller becomes controllable via communicatively transparent d-environment.

[0143] IDE-IDC includes the developing applications related to as Software of Distributed Configuration (SDC) 12 and Software of Distributed Linking (SDL) 13 of the developed IDC. As well as for the general-purpose computer includes the integral development kit of the IFD devices mounted in IDC controller.

[0144] As well as for the general-purpose computer includes Supervisory Control and Data Acquisition, SCADA, applications, (SCADA-IDC), whereby the integral controlling of the distributed functional tasks integrated in the industrial process is provided. In this way as the control program as the control subprograms could be developed and updated.

[0145] The special general-purpose computer configuration or / and special computer structure for operating IDC controller are in the scope of the present invention.

[0146] IDC compiling

[0147] Referring back to Figs. 1 and 3, in order to compile IDC 10 operating in a coherent manner, the following procedures are performed:

[0148] 1. Software stage: a configuration of each IFD lOO.i is developed in accordance with single task function and location; 2. Programming stage: the developed configuration is translated to each IFD lOO.i in order to physically configure IDC 10;

[0149] 3. Testing and control stage: correspondence the physical structure of IDC 10 to the developed configuration is checked and debugged as needed.

[0150] Specifically, each IFD device lOO.i is assigned via d-label programmed in the corresponding configured memory of its d-microcontroller for identifying the minimal set of the following attributes:

[0151] a. a locality IFD device in space of IDC controller based on space-defined X, Y, Z coordinates of the locations of IFD devices lOO.i;

[0152] b. a functionality including the functional data is a directive word (e.g. like to configuring word implemented in MPASM) describing the single-task digital twin of functional module 110 of the IFD device for controlling;

[0153] The programmed connection of specific IFD device lOO.i is defined by linking data, which is generated in accordance with the minimal set of attributes.

[0154] EXAMPLE:

[0155] At the first step, the control program 200 as a sequence of the control subprograms 200.i related to the plurality of the IFD devices lOO.i is built in a software runtime of the general -purpose computer by virtual manner. The physical (industrial) space occupied by IFD devices lOO.i is mapped via e.g. 7-byte space coordinates where X-longitude may be defined by 3 byte, Y-latitude may be defined by 3 bytes, and Z-altitude may be defined 1 byte (+- 128 bit). Therefore, each IFD lOO.i is attributed with a unique 7-byte identifier. The data used for configuring a d-microcontroller is presented in Table 1.

[0156] Table 1

[0157] Configuring data for d-microcontroller

[0158] Label: {d}

[0159] Locality {X, Y, Z}

[0160] Functional data: {f: pressure}

[0161] Program portion

[0162] Locality {d: P}

[0163]

[0164] The length of d-label is restricted by e.g. 2-byte. Correspondingly, the number of IFD devices lOO.i must not exceed 2-byte d-label length.

[0165] At the next step, the localities and functional data via Software of Distributed Configuration (SDC) 12 and Software of Distributed Linking (SDL) 13 tools are linked in configuration data identified by d-label 300.i for each IFD device lOO.i as arranged in the map. The configuration data are stored in the SDC 12, but the d-label is loaded into d-microcontroller of each IFD device lOO.i, which is configured and farther mounted in IDC controller 10 within the physical industrial process space.

[0166] At the next step, the SDL 13 adopts the configuration data and d-labels for generating a linking data for setting programming e.g. the routing table 152 of switchable d-router 150 providing integral communicability of each IFD device lOO.i in IDC controller 10, which farther are recorded in the SDC 12 and SDL 13. The linking data used for directive-type instructions defining the routes is presented in Table 2.

[0167] Table 2

[0168] Linking data for routing tables of d-p-interfaces

[0169] From p1 goto p16 p1:p16 =={d6:d3:d1};

[0170] From p2 goto p9 p2:p9 =={d3:d1:d8:d16:d15};

[0171]

[0172] Each IFD device lOO.i is reconfigurable via by means of upgrading the configuration data. Referring back to Fig. 3, each pair of the neighboring IFD devices lOO.i communicates with each other via p-and-d-interfaces for setting the bit, byte and frame synchronization in IDC controller 10, and for controlling the data route there through, and which can be re-routed in term of error, upgrading or end-of-life scenarios of the IFD devices lOO.i respectively.

[0173] At the next step, the IFD devices lOO.i are installed in the corresponding location of the IDC controller 10. Finally, the software and physical arrangement are verified, tested, and debugged via data communications between d-microcontrollers via d-routers. The d-labels of the sender and receiver are applied for heading data packets with directive-type instructions, which include the instructions, opcode, and data for farther processing. Note that, in practical designing aspects a modeling bench 400 of a plurality of the IFD devices lOO.i simulators via control subprograms 200.i thereof shown in Fig. 3 can be used for preliminary modelling IDC controller 10.

[0174] An integral controllers stitching

[0175] Reference is now made to Figs 4a and 4b illustrating a number of the IDC controllers lO.j (m,n) deployed in a physical area and including a number of IFD devices lOO.i more than d-label length. Each IDC controller 10 is considered as an enclosing system including the nested IDC controllers lO.j (m, n) enclosing the nested IFD devices lOO.i.

[0176] According to the invention, a number of IDC controllers m,n is stitched by connecting neighboring IFD devices belonging to a pair of the neighboring IDC controllers respectively (m,n and m+l,n in accordance to Fig. 4a and 4b); p-interfaces and d-interfaces 170 are separately interconnected via cable links 171 and 172 shown in Fig. 2. Then, when the neighboring IFD devices lOO.i are compiled, the first IFD device lOO.i of neighboring IDC controller m,n becomes the last IFD device lOO.i of neighboring IDC m+l,n. The configuring and linking data are updated, respectively.

[0177] 7 Control program compiling

[0178] IDC controller 10 enables compiling and executing control program 200 associated with the distributed in physical area a plurality of the single dedicated functional tasks.

[0179] Referencing back to Figs. 1 and 3, according to the programming aspects, each control subprogram 200.i of the control program 200 is the control subprogram, which is executed independently one the others. The control subprograms 200.i is identified by the program p-label (label i). In other words, contrary to the Internet approach, the control subprograms 200.i are the communicating objects, identified by p-labels, executable and communicable in a predetermined coherent manner.

[0180] In order to execute a certain number of the control subprograms 200.i, the same number of IFD devices lOO.i is required. The IFD devices lOO.i and links between them are controlled by the SDC 12 and the SDL 13 executed in the general -purpose computer 11 where the records regarding d-labels 300.i and p-label i 200.i of the IFD devices lOO.i are generated. In order to launch the control program 200, the links along the routed IFD devices lOO.i are programmed into routing tables 132 of p-switches (of p-routers) to build the routes between those IFD devices executing a sequence of the control subprograms 200.i to be executed in accordance with control algorithm of the control program 200.

[0181] In practical aspects, the control subprograms 200.i can be preinstalled via the embedded corresponding software environment 121 of p-microcontroller 120 configured for executing thereof with setting parameters 122, by the manufacturer, i.e. factory setting.

[0182] The distributed control program 200 runs in the space of the IDC controller 10 by sending only and only the subprogram p-labels, analogously to the program instruction “goto [label], in our case goto [label i]” along the sequence of the IFDs devices lOO.i involved in the execution of the control program via IDC p-environment thereof.

[0183] Herein, program p-label relates to the ended on-task program portion 200.i, thus

[0184] a. Logic security is provided, when data relating to the previous event that has already happened is sent for initiating the next event;

[0185] b. In the case of a fault of IFD device dedicated to execution the next control subprogram, an alternative industrial control strategy including initiating alternative control subprogram in an alternative IFD device respectively could be determined for rearranging said control program sequence. The emergency strategies are pre-installed. Controlling services and / or utilities deployed at a national or global territory, publicly or privately managed are in the scope of the present invention.

[0186] The separated p-d structure of the IFD devices integrated in distributed IDC controller is suitable for industrial control, packet switching telephony, and communicating and controlling packetized data of the HTTP type.

[0187] As mentioned above IDC controller is the complex distributed but entire all-in-one computer, such as PC, laptop computers, and can be implemented like these.

[0188] It is possible to embody the invention in specific forms other than those of the preferred embodiment described above. This may be done without departing from the spirit of the invention. The preferred embodiment is merely illustrative, and it should not be considered restrictive in any way. The foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed. It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

Claims:

1. A method for integral controlling of an industrial process, comprising at least the following steps:a. dedicating the distributed functional tasks of the industrial process for controlling thereof, where are each of the dedicated functional tasks uninterrupted by other dedicated functional tasks in said controlling, wherein each of said dedicated functional tasks is defined by a location label in space of said industrial process; b. providing a digital interface for said each of the dedicated functional tasks to digitally control therefor;c. providing the corresponding control subprograms to control said dedicated functional tasks via said digital interfaces thereof, respectively, wherein each of said corresponding control subprograms is uninterrupted by other of said corresponding control subprograms in executing thereof;d. compiling said corresponding control subprograms in a control program, wherein each of said corresponding control subprograms is defined by a corresponding program label, whereby said corresponding control subprograms are intercommunicated one other for running said control program;e. providing a subprogram communicating interface for each of said corresponding control subprograms, whereby said corresponding control subprograms are communicativeable;f. providing a controlling algorithm, whereby said corresponding control subprograms are intercommunicated one other via said subprogram communicating interface for running said control program, wherein said corresponding control subprograms are intercommunicated one other by applying said program labels thereof; g. integrating at least the corresponding digital interface, corresponding control subprogram and subprogram communicating interface defining the corresponding dedicating functional task to configure a corresponding integral field device, IFD,provided with an embedded software executing facilities, whereby each of steps (a) - (g) is accomplished for controlling said corresponding dedicated functional task; h. embedding IFD controlling interface in said corresponding IFD, whereby each of steps (a) - (g) is controlled;i. locating said corresponding IFD in the location of said corresponding dedicated functional task to be controlled therefor;j. integrating a corresponding plurality of said corresponding IFDs, where are each located in the location of the corresponding dedicated functional task, to configure a single integral distributed controller, IDC, whereinthe IFD controlling interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure the distributed software runtime operating environment, the subprogram communicating interfaces of said corresponding plurality of said corresponding IFDs is integrated to configure a control program runtime environment, for said integral controlling of said industrial process, respectively;k. configuring said IFD controlling interface embedded into each of said corresponding IFDs of said IDC to control and acquire data of each of said corresponding IFDs and dedicated functional tasks to be controlled thereby, wherein said data is provided via said software runtime operating environment for other corresponding IFDs and dedicated functional tasks to be controlled thereby, in said IDC for said integral controlling of the industrial process, respectively;l. providing Integrated Development Environment for developing each of steps (a) - (k).

2. An integral field device, IFD, providing to accomplish the integral controlling of the corresponding dedicated functional task of the industrial process in accordance with claim 1, said IFD device comprises at least:a. an industrial functional task controlling module (p-module), comprisesa functional microcontroller (f-microcontroller), a subprogram executing microcontroller (p-microcontroller) and a subprogram communicating microcontroller (p-router), thereinsaid p-microcontroller communicatively coupled with said f-microcontroller in local controlling aspects, and communicatively coupled with said p-router in integral controlling aspects, respectively,said f-microcontroller includes at least the embedded corresponding software runtime environment configured to provide a digital interface to said corresponding dedicated functional task for controlling thereof in said local controlling aspects,said p-microcontroller includes at least the embedded corresponding software runtime environment configured for executing the installed therein corresponding control subprogram controlling said dedicated functional task via said f-microcontroller digital interface in local controlling aspects, and via said p-router in integral controlling aspects, respectively, said corresponding control subprogram is defined by the corresponding communicative label (p-label);said p-router includes at least the embedded corresponding software runtime environment configured to provide a data packets switching circuit (p-switch) with one or more data communicating interfaces of the physical layer type (p-interface), whereby said corresponding control subprogram intercommunicates by applying said p-label thereof;b. an operational module (d-module) comprisesa directives processing microcontroller (d-microcontroller), and directives communicating microcontroller (d-router),whereinsaid d-microcontroller includes at least the embedded corresponding software runtime environment configured for processing the directives of data acquire and control each microcontroller of said p-d modules in response to the corresponding inbound directive instructions and to send outbound directive instructions, in said local and integralcontrolling aspects, said d-microcontroller is defined by the corresponding location label (d-label);said d-router includes at least the embedded corresponding software runtime environment configured to provide a data packets switching circuit (d-switch) with one or more data communicating interfaces of the physical layer type (d-interface), whereby said corresponding inbound directive instructions and outbound directive instructions are communicated by applying said d-label;c. an interior control and data acquisition bus (IFD-bus), whereinsaid f-microcontroller, p-microcontroller, d-microcontroller, p-router and d-router are each provided with selectable in-circuit control and data acquisition interface to be coupled with said IFD-bus to be selectively controllable and data acquirable.

3. An integral distributed controller, IDC, providing to accomplish the integral controlling of the industrial process in accordance with claim 1, said IDC controller has at least a software runtime operating environment and a control program runtime environment, said IDC controller comprisesa plurality of the distributed integral field devices, IFD, are each of claim 2, distributed for the integral controlling of the industrial process, whereineach pair of the neighboring IFD devices of said plurality of the distributed IFD devices are connected one other via at least one d-interface of said d-switch, of said d-routers respectively, whereby the d-microcontrollers of said plurality of the distributed IFD devices are communicable with each other providing said software runtime operating environment (d-environment), wherein said d-labels of said IFD devices are applied for intercommunicating said directive type instructions, respectively;each pair of said neighboring IFD devices of said plurality of the distributed IFD devices are connected one other via at least one p-interface of said p-switch, of said p- routers respectively, whereby said p-microcontrollers of said plurality of the distributed IFD devices are communicable with each other providing said control program runtime environment (p-environment), wherein said p-labels of the corresponding control subprograms are intercommunicated, respectively;4. A method of configuring IDC controller of claim 3, said method comprises at least the operations of:a. providing a plurality of IFD devices in accordance to said dedicated functional tasks of said industrial process;b. generating d-labels identifying each IFD device in accordance to locations of said dedicated functional tasks in said industrial process;c. generating a routing data by compiling said d-labels in the linking sequences, whereby the d-labeled IFD devices link with each other in said plurality of IFD devices;d. initializing each IFD device of said plurality of IFD devices for integrating in said IDC controller, said initializing further comprising:i. loading an d-label into a d-microcontroller;ii. installing said routing data of d-labels into a d-router;iii. adopting said d-labels for communicating said IFD devices with each other; e. mounting said each IFD device of said plurality of IFD devices in said dedicated functional tasks locations;f. applying said d-labels to head the data packets for delivering said data packets to said mounted IFD devices via said d-environment in accordance to said routing data;g. checking the physical correspondence of mounted IFD devices by said delivering said data packets to said IFD devices respectively;h. configuring said mounted IFD devices to implement one or more integral control strategies for integral controlling of the industrial process;5. The method in accordance with claim 4, wherein said operation (c) further comprises the operations of providing alternative said routing data by said compiling said d-labels;6. A method in accordance with claim 4, further comprising the operations of integrating at least two neighboring IDC controllers:a. selecting pairs of said neighboring IDC controllers to be integrated in neighboring spatial areas;b. selecting pairs of neighboring IFD devices each belonging to different neighboring IDC controllers in said pairs of neighboring IDC controllers;c. integrating said neighboring IFD devices within said selected pairs of neighboring IFD devices within selecting pairs of neighboring IDC controllers, respectively;7. A method of compiling a control program for the integral controlling of the industrial process in accordance with claim 1, by at least one IDC controller of claim 3 configured in accordance with claim 4, said method comprises at least the operations of:a. defining IFD devices to execute the corresponding control subprograms to be compiled in said control program, in said at least one IDC controller; b. developing a control algorithm of said control program whereby to implement one or more integral control strategies for integral controlling said industrial process, wherein said corresponding control subprograms to be compiled interoperate with each other;c. assigning the program labels (p-label) for each of said corresponding control subprograms;d. configuring said p-labels in accordance with d-labels of said IFD devices;e. generating a routing data by compiling said p-labels in the linking sequences of the p-labeled corresponding control subprograms in accordance to said control algorithm of said control program, respectively;f. installing said p-labels of said corresponding control subprograms into p- microcontrollers of said IFD devices via said d-environment of said at least one IDC controller;g. installing said routing data into p-routers of said IFD devices via said d- environment of said at least one IDC controller;h. providing to run said control program by said IFD devices executing said corresponding control subprograms, respectively in accordance with said control algorithm of said control program in said at least one IDC controller;8. The method as claim in 7, wherein said operation (e) further comprises the operations of providing alternative said routing data by said compiling said p-labels;9. The method as claim in 7, wherein the operation (h) comprises the execution of the previous and next corresponding control subprograms executed by the executing IFD devices consecutively, wherein the dedicated p-label of said previous corresponding control subprogram is sent, via p-environment of said at least one IDC controller, in response to ending thereof for executing said next controlling control subprogram executed in accordance to said control algorithm.

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