WO2000077583A1 - Control system with improved installation - Google Patents

Control system with improved installation Download PDF

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Publication number
WO2000077583A1
WO2000077583A1 PCT/US2000/016152 US0016152W WO0077583A1 WO 2000077583 A1 WO2000077583 A1 WO 2000077583A1 US 0016152 W US0016152 W US 0016152W WO 0077583 A1 WO0077583 A1 WO 0077583A1
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WO
WIPO (PCT)
Prior art keywords
component
control system
components
information
transfer
Prior art date
Application number
PCT/US2000/016152
Other languages
French (fr)
Inventor
Thomas B. Kinney
T. Eric Christiansen
Peter D. Hansen
Bo Ling
Paul C. Badavas
Richard L. Thibault
Original Assignee
The Foxboro Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/345,215 external-priority patent/US6501995B1/en
Application filed by The Foxboro Company filed Critical The Foxboro Company
Priority to AU54839/00A priority Critical patent/AU5483900A/en
Publication of WO2000077583A1 publication Critical patent/WO2000077583A1/en

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Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F8/00—Arrangements for software engineering
    • G06F8/60—Software deployment
    • G06F8/65—Updates
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/23—Pc programming
    • G05B2219/23306—Load program from host, remote load, non volatile card to volatile, ram
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/25—Pc structure of the system
    • G05B2219/25014—Fieldbus general name of bus connected to machines, detectors, actuators
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/25—Pc structure of the system
    • G05B2219/25092—Customized control features, configuration
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31104—Remote configuration of parameters of controlled devices
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31156—Network structure, internet
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31161—Java programcode or simular active agents, programs, applets
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31422—Upload, download programs, parameters from, to station to, from server
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/34—Director, elements to supervisory
    • G05B2219/34038—Web, http, ftp, internet, intranet server
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/34—Director, elements to supervisory
    • G05B2219/34259—Common language run time CLR, MS-NET, DOTNET, java run time environment
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F11/00—Error detection; Error correction; Monitoring
    • G06F11/07—Responding to the occurrence of a fault, e.g. fault tolerance
    • G06F11/16—Error detection or correction of the data by redundancy in hardware
    • G06F11/20—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements
    • G06F11/202—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements where processing functionality is redundant
    • G06F11/2038—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements where processing functionality is redundant with a single idle spare processing component
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F11/00—Error detection; Error correction; Monitoring
    • G06F11/07—Responding to the occurrence of a fault, e.g. fault tolerance
    • G06F11/16—Error detection or correction of the data by redundancy in hardware
    • G06F11/20—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements
    • G06F11/202—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements where processing functionality is redundant
    • G06F11/2048—Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements where processing functionality is redundant where the redundant components share neither address space nor persistent storage
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the invention pertains to control systems and, more particularly, to methods and apparatus for distributing, installing and/or validating components of such systems.
  • control and “control systems” refer to the control of a device or system by monitoring one or more of its characteristics. This is used to insure that output, processing, quality and/or efficiency remain within desired parameters over the course of time.
  • digital data processing or other automated apparatus monitor the device or system in question and automatically adjust its operational parameters.
  • such apparatus monitor the device or system and display alarms or other indicia of its characteristics, leaving responsibility for adjustment to the operator.
  • Control is used in a number of fields.
  • Process control for example, is typically employed in the manufacturing sector for process, repetitive and discrete manufactures, though, it also has wide application in electric and other service industries.
  • Environmental control finds application in residential, commercial, institutional and industrial settings, where temperature and other environmental factors must be properly maintained.
  • Control is also used in articles of manufacture, from toasters to aircraft, to monitor and control device operation.
  • one of the CPs is placed in active mode, while its partner is being upgraded.
  • the upgraded unit is then brought on-line, but only in shadow mode. Its operation is monitored by the engineer or operator, e.g., who compares its output with that of the active CP. If satisfied with the upgraded unit, the engineer can make it active, so that the remaining original CP can be upgraded. Redundant, fault-tolerant operation resumes once both CPs are similarly upgraded.
  • An object of this invention is to provide methods and apparatus that overcome these shortcomings. More particularly, an object is to provide improved methods and apparatus that facilitate the distribution, installation and validation of control systems and components.
  • a further object of the invention is to provide such methods and apparatus as facilitate the installation of components into active or on-line control systems.
  • a still further object of the invention is to provide such methods and apparatus as facilitate the distribution of control system components, e.g., from a manufacturer's site, and their installation, e.g., at a remote site.
  • Yet a still further object of the invention is to provide such methods and apparatus as can be readily implemented on existing digital data processing apparatus or special purpose control apparatus.
  • Still yet further related objects of the invention are to provide such methods and apparatus as can be applied in process control systems, environmental control systems, and the like.
  • control system with blocks or other components that facilitate validation of their own replacements.
  • Further aspects of the invention provide control systems in which the components to be validated are downloaded and installed from a remote site, e.g., via e-commerce transaction.
  • the invention provides a control system that includes first and second control components, e.g., flow control objects for a process control system.
  • the first component is coupled to a third control component, with which it transfers information, e.g., as part of an active or ongoing control process.
  • the third component can be, for example, a temperature control object with which the first component (e.g., a flow control object) is in a cascaded arrangement.
  • the second component can be, for example, an update or other potential replacement for the first component.
  • the second component can be a similar control object with new or improved functionality.
  • the first and/or second components of a control system can effect substitution of the second component for the first. More particularly, they can effect coupling of the second component for information transfer with the third component and decoupling of the first component from such transfer with the third component. Preferably, such coupling and decoupling occur while the control system remains active.
  • the second component prior to its substitution for the first component, is coupled to receive information from the third component and/or any sources from which the first component receives information.
  • the second component is at least temporarily prevented from outputting information to any sinks to which the first component sends information.
  • the output of the second component can be routed, along with that of the first component, to one or more comparators. These can reside elsewhere in the control system, e.g., in a supervisor object, or within the first and/or second components themselves. Substitution of the second component for the first rests on the success of comparison of their outputs and, in most applications, on confirmation by the operator or test engineer.
  • a comparator can check the output of a newly installed flow control object against the output of an old object it is intended to replace.
  • the comparator can notify the operator of the results of the comparison and, if the operator approves, the new object can be substituted for the old.
  • a list maintained in the first component can identify its various parameters that are sinks for the third component and, likewise, parameters in the third (or other components) for which it (the first component) is the source.
  • Substitution of the second component for the first may be effected, for example, by replacing all connections to/from the first component with connections to/from the second component.
  • Still further aspects of the invention provide a control system as described above in which the first and second components are resident on a control processor, a "smart" field device, or on another digital data processor-based control device.
  • the configured second component can be downloaded to that device, e.g., from a control system work station, while the control system is active and while the first component is operational, e.g., exchanging information with the third component.
  • downloading from a manufacturer's site to the workstation can be effected as part of a contracted-for maintenance transaction, an upgrade transaction and or as part of an e-commerce transaction, e.g., between the customer and the manufacturer.
  • Such downloading moreover, can be instigated by the customer or, automatically, by the first component or a software agent within the control system.
  • Yet still further aspects of the invention provide methods for control and methods for distributing and/or installing control components paralleling the operations described above.
  • Figure 1 depicts a plurality of networked digital data processors for use in practicing the invention
  • Figure 2 depicts objects for controlling a process in a system according to the invention.
  • Figures 3A-3C depict the insertion and validation of a replacement object in the process control system of Figure 2.
  • Figure 1 depicts a digital data processing system of the type with which the invention may be practiced.
  • the system includes a controller or other digital data processor 10 on which resides a process control system for monitoring or controlling a process 12.
  • digital data processor 10 represents one or more workstations, controllers, microprocessors, embedded processors, "smart" field devices, or other digital data processing apparatus, utilized to control or monitor a process.
  • Such digital data processing apparatus are of the types commercially available in the marketplace, operated in accord with the teachings herein to facilitate process control component installation and/or validation.
  • Medium 14 provides for transport, from site 16, of process control components ⁇ and, more particularly, software aspects thereof — that are to be installed and executed on digital data processor 10. Though illustrated to represent a LAN, WAN, or global network (Internet), those skilled in the art will appreciate that element 14 may represent any medium or mechanism through which software may be transported, electronically, physically or otherwise, from site 16 to digital data processor 10 or workstation 11.
  • Site 16 represents any source of software-based process control components or definitions thereof. This can include, for example, a retail store, warehouse or other distribution point of CDROMs, diskettes or other magnetic medium on which components or their definitions are stored. In a preferred embodiment, however, it represents a digital data processor that functions as a server, e.g., maintained by a manufacturer or other distributer, from which such components can be electronically transported to the digital data processor 10 or workstation 11. Without detracting from breadth of the teachings herein, site 16 is referred to hereinafter as a "site server.”
  • Process 12 represents any industrial, manufacturing, service, environmental or other process amenable to monitoring or control (hereinafter, collectively, "control"). This is illustrated in greater detail in Figure 2. wherein a simple such process is shown as including valve 18 that governs the rate of fluid flow to aeration tank 20 which, in turn, transfers the liquid to storage tank 22. Sensors 24 and 26 monitor the state of process 12 and, thereby, facilitate its control by process control system 28 operating on the one or more digital data processors represented by element 10. Thus, sensor 24 is disposed in or adjacent to tank 20 for measuring the temperature of fluid therein, while sensor 26 measures the flow of fluid from aeration tank 20 to storage tank 22.
  • control monitoring or control
  • FIG. 2 illustrates a sample process control system 28 in which the invention is employed.
  • the system 28 includes three process control components 29, 30, 32 which, themselves, may include further components (not shown).
  • Components 29, 30, 32 may comprise any combination of software and hardware features.
  • OOP object-oriented programming
  • Other software constructs, by way of non-limiting example, DLL files, may be employed as well.
  • the workstation 11 or supervisor object 29 may initiate process control functions, including activation and execution of process control objects 30 and 32.
  • the supervisor object 29 generates a temperature supervisory setpoint, e.g., based on operator input or a supervisory program.
  • Object 30 serves as a temperature controller that utilizes a proportional-integral- derivative (PID) or other control algorithm to generate a flow remote setpoint based on the temperature setpoint from the supervisor object 29 and on temperature readings from sensor 24.
  • Object 32 serves as a flow controller that, too, utilizes a PID or other control algorithm to generate a flow level based on the flow setpoint from object 30 and on flow readings from sensor 26.
  • Objects 29, 30, 32 operate in the conventional manner known in the art, as modified in accord with the teachings herein to facilitate installation and/or validation of a further such component, e.g., replacement object 30a ( Figure 3).
  • supervisor 29 is referred to as a "source” for PID 30 and, more accurately, for the temperature setpoint parameter used by PID 30.
  • Temperature sensor 24 is also a source for PID 30.
  • PID 32 is, conversely, referred to as a "sink” for PID controller 30 and. more accurately, for the flow setpoint parameter generated by it.
  • sources i.e., suppliers
  • sinks i.e., consumers
  • the identities of the respective sources and sinks are maintained in centralized or distributed stores, e.g., pointers, symbols, variables, matrices, arrays, tables, records, databases, files, in the process control system 28.
  • a centralized table (not shown), accessible by all of the components, stores those identities.
  • each element maintains information about its own sources and/or sinks.
  • component 30 maintains pointers, addresses and/or identifiers of its various parameters that are sinks for information generated by the other components, e.g., elements 29 and 32. It also maintains pointers, addresses and/or identifiers of the components for which it (i.e., component 30) is a source. This facilitates reconnection of any components (e.g., 29. 32) that may be affected by replacement of component 30.
  • FIGS 3A-3C depict a methodology for the insertion and validation of a replacement component in the process control system 28.
  • Each drawing shows the system 28 in reduced format, using numeric labels to refer to the same-number blocks of Figure 2.
  • the components of the system 28 may, as noted above, reside on one or more digital data processing apparatus 10.
  • a new or replacement component 30a is added to system 28, e.g., to the same digital data processor as resides component 30 which it (component 30a) will replace.
  • component 30a comprises an OOP object
  • an OOP class definition comprising an object template and methods is transmitted from the server 16 to a workstation 11, e.g., as part of a contracted-for maintenance transaction, upgrade transaction, or e-commerce transaction.
  • an operator or engineer instantiates a replacement object 30a from the new class and configures the object for use in controlling process 12 via controller 10. Once configured, the object is downloaded to the controller, where it replaces a prior object 30 as described in further detail below.
  • the replacement object may be downloaded to digital data processor 10 via other mechanisms, as well.
  • the object definition or preconfigured object may be downloaded directly from server 16 to the digital data processor 10.
  • alternate data structures or code constructs e.g., DDL files
  • workstation 11 may be downloaded to processor 10 directly or via workstation 11.
  • step 1 an operator utilizes workstation 11 to send an inquiry to site server 16.
  • step 2 preferably occur while the process control system 28 is online and operational, e.g., controlling process 12, and without substantive disruption or delay of any of the monitor and/or control functions performed by the replaced component, or of any components in communication therewith.
  • substantially disruption or delay refers to any disruption or delay having more than negligible impact on the aforesaid monitor and/or control functions.
  • step 2 the site server 16 responds with information regarding possible upgrades.
  • the server 16 can provide a complete listing of available upgrades or, alternatively, only those applicable to process control system 28.
  • step 3 the operator selects a desired upgrade (e.g., the class for component 30a) and provides requisite purchase account information, e.g., credit card, PO number, etc. The operator also supplies whatever additional information is required or desirable in order to effect the download from the server 16.
  • step 4 the site server 16 downloads the replacement software to workstation 11, e.g.. in the form of a .Java file, a .class file, a DLL file (e.g., for non-OOP implementations), or in any other format suitable for adding software aspects of component 30a to workstation 11.
  • step 5 workstation 11 instantiates and configures component 30a, based on the new class, to be similar to component 30 and downloads it for testing in the control processor 10.
  • the downloaded component 30a is coupled to the sources of the block 30a that it is intended to replace, i.e., block 30.
  • the component is downloaded in the form of a JAVA ".class” file and, hence, it is immediately operational for purposes for such coupling.
  • additional steps such as compilation, linking/loading, etc. required to bring component 30a into existence on digital data processor 10 and/or to make it available for coupling into control system 28 can be effected at this time.
  • Routing can be effected by adding additional sinks to blocks 30, 30a, i.e., by defining them as sources for the comparator, or otherwise. Apart from routing its outputs to the comparator, replacement object 30a is temporarily prevented from applying those outputs to other components, e.g., 29, 32, in the system.
  • block 30a processes inputs received identically with block 30 and generates output comparable with that of block 30. Comparison can be performed in any manner known in the art, preferably, using comparison methodologies defined in the newly instantiated object 30a, in the original block 30, or elsewhere in the system. In the illustrated embodiment, graphical or other output indicative of the comparison is generated by the comparator for routing to a log and or to the operator workstation 11.
  • the foregoing operations are effected by executing sequences of the type that follow on the workstation 11 and control processor 10:
  • Control Processor 1. Download new class files.
  • the comparison phase can involve matching the output of potential replacement object 30a with a standard other than the output of object 30.
  • replacement components can be downloaded directly to a controller or other digital data processing apparatus in which thev are to be executed.

Abstract

A control system has blocks (30) or other components that facilitate validation of their own replacements, e.g., downloaded via e-commerce transactions (11). The system includes first (30) and second (30a) process control components. The first component is coupled to a third process control component (32), with which it transfers information, e.g., as part of an active or ongoing control process. The second component (30a) can be, for example, an update or other potential replacement for the first component. The first and/or second components can effect substitution of the second component for the first. More particularly, they can effect coupling of the second component for information transfer with the third component and decoupling of the first component from such transfer with the third component. Preferably, such coupling and decoupling occur while the process control system remains active.

Description

CONTROL SYSTEM WITH IMPROVED INSTALLATION
Background of the Invention
The invention pertains to control systems and, more particularly, to methods and apparatus for distributing, installing and/or validating components of such systems.
The terms "control" and "control systems" refer to the control of a device or system by monitoring one or more of its characteristics. This is used to insure that output, processing, quality and/or efficiency remain within desired parameters over the course of time. In many control systems, digital data processing or other automated apparatus monitor the device or system in question and automatically adjust its operational parameters. In other control systems, such apparatus monitor the device or system and display alarms or other indicia of its characteristics, leaving responsibility for adjustment to the operator.
Control is used in a number of fields. Process control, for example, is typically employed in the manufacturing sector for process, repetitive and discrete manufactures, though, it also has wide application in electric and other service industries. Environmental control finds application in residential, commercial, institutional and industrial settings, where temperature and other environmental factors must be properly maintained. Control is also used in articles of manufacture, from toasters to aircraft, to monitor and control device operation.
Digital data processing is firmly entrenched in the control systems. System designers increasingly rely on software to add functionality and flexibility to their systems. The installation and validation of process control system components, for example, has generally been quite simplistic. When a new hardware component is to be installed, an operator or test engineer must take the system offline, install the new component, bring the system back online, and monitor the operation of the component. If satisfied, the engineer makes the installation permanent. The I/A Series process control systems, manufactured by the assignee hereof, represent a major advance in this technology. They utilize a fault-tolerant architecture in which each control processor (CP), for example, has a redundant, shadow partner. Either of the partners can be replaced or updated while the system is still in operation. To this end, one of the CPs is placed in active mode, while its partner is being upgraded. The upgraded unit is then brought on-line, but only in shadow mode. Its operation is monitored by the engineer or operator, e.g., who compares its output with that of the active CP. If satisfied with the upgraded unit, the engineer can make it active, so that the remaining original CP can be upgraded. Redundant, fault-tolerant operation resumes once both CPs are similarly upgraded.
While the prior art techniques have proven effective to date, the ever increasing complexity of control systems render those techniques problematic. The physical replacement of hardware components, for example, can render maintenance unduly costly. This is exacerbated if the engineer must remain at a remote site until validation of the replacement is complete.
The replacement of software components is only somewhat less demanding. Apart from the aforementioned I/A Series systems, the prior art typically demands that an entire system be upgraded or, at least, taken off-line in order for an upgrade to be performed and tested. Moreover, the replacement of software components in prior art systems requires that the engineer be present at the replacement site, remaining there until the replacement is validated.
An object of this invention is to provide methods and apparatus that overcome these shortcomings. More particularly, an object is to provide improved methods and apparatus that facilitate the distribution, installation and validation of control systems and components.
A further object of the invention is to provide such methods and apparatus as facilitate the installation of components into active or on-line control systems.
A still further object of the invention is to provide such methods and apparatus as facilitate the distribution of control system components, e.g., from a manufacturer's site, and their installation, e.g., at a remote site.
Yet a still further object of the invention is to provide such methods and apparatus as can be readily implemented on existing digital data processing apparatus or special purpose control apparatus.
Still yet further related objects of the invention are to provide such methods and apparatus as can be applied in process control systems, environmental control systems, and the like.
Summary of the Invention
The foregoing are among the objects attained by the invention, which provides in one aspect a control system with blocks or other components that facilitate validation of their own replacements. Further aspects of the invention provide control systems in which the components to be validated are downloaded and installed from a remote site, e.g., via e-commerce transaction.
Thus, in one aspect, the invention provides a control system that includes first and second control components, e.g., flow control objects for a process control system. The first component is coupled to a third control component, with which it transfers information, e.g., as part of an active or ongoing control process. The third component can be, for example, a temperature control object with which the first component (e.g., a flow control object) is in a cascaded arrangement. The second component can be, for example, an update or other potential replacement for the first component. Thus, for example, if the first component is a flow control object, the second component can be a similar control object with new or improved functionality.
The first and/or second components of a control system according to this aspect of the invention can effect substitution of the second component for the first. More particularly, they can effect coupling of the second component for information transfer with the third component and decoupling of the first component from such transfer with the third component. Preferably, such coupling and decoupling occur while the control system remains active.
According to a related aspect of the invention, prior to its substitution for the first component, the second component is coupled to receive information from the third component and/or any sources from which the first component receives information. The second component, however, is at least temporarily prevented from outputting information to any sinks to which the first component sends information. Instead, the output of the second component can be routed, along with that of the first component, to one or more comparators. These can reside elsewhere in the control system, e.g., in a supervisor object, or within the first and/or second components themselves. Substitution of the second component for the first rests on the success of comparison of their outputs and, in most applications, on confirmation by the operator or test engineer.
By way of example, a comparator can check the output of a newly installed flow control object against the output of an old object it is intended to replace. The comparator can notify the operator of the results of the comparison and, if the operator approves, the new object can be substituted for the old.
Further aspects of the invention provide a control system as described above in which one or more stores, e.g., pointers, symbols, variables, matrices, arrays, tables, records, databases, files, or other information stores, identify relationships between components and, more particularly, their respective sources and sinks. A list maintained in the first component, for example, can identify its various parameters that are sinks for the third component and, likewise, parameters in the third (or other components) for which it (the first component) is the source. Substitution of the second component for the first may be effected, for example, by replacing all connections to/from the first component with connections to/from the second component.
Still further aspects of the invention provide a control system as described above in which the first and second components are resident on a control processor, a "smart" field device, or on another digital data processor-based control device. The configured second component can be downloaded to that device, e.g., from a control system work station, while the control system is active and while the first component is operational, e.g., exchanging information with the third component. By way of further example, downloading from a manufacturer's site to the workstation can be effected as part of a contracted-for maintenance transaction, an upgrade transaction and or as part of an e-commerce transaction, e.g., between the customer and the manufacturer. Such downloading, moreover, can be instigated by the customer or, automatically, by the first component or a software agent within the control system. Yet still further aspects of the invention provide methods for control and methods for distributing and/or installing control components paralleling the operations described above.
Brief Description of the Drawings
A more complete understanding of the invention may be attained by reference to the drawings, in which:
Figure 1 depicts a plurality of networked digital data processors for use in practicing the invention;
Figure 2 depicts objects for controlling a process in a system according to the invention; and
Figures 3A-3C depict the insertion and validation of a replacement object in the process control system of Figure 2.
Detailed Description of the Illustrated Embodiment
Figure 1 depicts a digital data processing system of the type with which the invention may be practiced. The system includes a controller or other digital data processor 10 on which resides a process control system for monitoring or controlling a process 12. Though only one element is shown, those skilled in the art will appreciate that digital data processor 10 represents one or more workstations, controllers, microprocessors, embedded processors, "smart" field devices, or other digital data processing apparatus, utilized to control or monitor a process. Such digital data processing apparatus are of the types commercially available in the marketplace, operated in accord with the teachings herein to facilitate process control component installation and/or validation.
Medium 14 provides for transport, from site 16, of process control components ~ and, more particularly, software aspects thereof — that are to be installed and executed on digital data processor 10. Though illustrated to represent a LAN, WAN, or global network (Internet), those skilled in the art will appreciate that element 14 may represent any medium or mechanism through which software may be transported, electronically, physically or otherwise, from site 16 to digital data processor 10 or workstation 11.
Site 16 represents any source of software-based process control components or definitions thereof. This can include, for example, a retail store, warehouse or other distribution point of CDROMs, diskettes or other magnetic medium on which components or their definitions are stored. In a preferred embodiment, however, it represents a digital data processor that functions as a server, e.g., maintained by a manufacturer or other distributer, from which such components can be electronically transported to the digital data processor 10 or workstation 11. Without detracting from breadth of the teachings herein, site 16 is referred to hereinafter as a "site server."
Process 12 represents any industrial, manufacturing, service, environmental or other process amenable to monitoring or control (hereinafter, collectively, "control"). This is illustrated in greater detail in Figure 2. wherein a simple such process is shown as including valve 18 that governs the rate of fluid flow to aeration tank 20 which, in turn, transfers the liquid to storage tank 22. Sensors 24 and 26 monitor the state of process 12 and, thereby, facilitate its control by process control system 28 operating on the one or more digital data processors represented by element 10. Thus, sensor 24 is disposed in or adjacent to tank 20 for measuring the temperature of fluid therein, while sensor 26 measures the flow of fluid from aeration tank 20 to storage tank 22.
Figure 2 illustrates a sample process control system 28 in which the invention is employed. The system 28 includes three process control components 29, 30, 32 which, themselves, may include further components (not shown). Components 29, 30, 32 may comprise any combination of software and hardware features. In the illustrated embodiment only software features are shown ~ here, as object-oriented programming (OOP) "objects." Other software constructs, by way of non-limiting example, DLL files, may be employed as well.
The workstation 11 or supervisor object 29 may initiate process control functions, including activation and execution of process control objects 30 and 32. The supervisor object 29 generates a temperature supervisory setpoint, e.g., based on operator input or a supervisory program. Object 30 serves as a temperature controller that utilizes a proportional-integral- derivative (PID) or other control algorithm to generate a flow remote setpoint based on the temperature setpoint from the supervisor object 29 and on temperature readings from sensor 24. Object 32 serves as a flow controller that, too, utilizes a PID or other control algorithm to generate a flow level based on the flow setpoint from object 30 and on flow readings from sensor 26. Objects 29, 30, 32 operate in the conventional manner known in the art, as modified in accord with the teachings herein to facilitate installation and/or validation of a further such component, e.g., replacement object 30a (Figure 3).
In process control terminology, supervisor 29 is referred to as a "source" for PID 30 and, more accurately, for the temperature setpoint parameter used by PID 30. Temperature sensor 24 is also a source for PID 30. PID 32 is, conversely, referred to as a "sink" for PID controller 30 and. more accurately, for the flow setpoint parameter generated by it. Like terminology can be applied to the other elements and parameters that are sources (i.e., suppliers) or sinks (i.e., consumers) of information produced within the system 12.
The identities of the respective sources and sinks are maintained in centralized or distributed stores, e.g., pointers, symbols, variables, matrices, arrays, tables, records, databases, files, in the process control system 28. In one embodiment, for example, a centralized table (not shown), accessible by all of the components, stores those identities.
In a preferred embodiment, each element maintains information about its own sources and/or sinks. Thus, for example, in the illustrated embodiment, component 30 maintains pointers, addresses and/or identifiers of its various parameters that are sinks for information generated by the other components, e.g., elements 29 and 32. It also maintains pointers, addresses and/or identifiers of the components for which it (i.e., component 30) is a source. This facilitates reconnection of any components (e.g., 29. 32) that may be affected by replacement of component 30.
Figures 3A-3C depict a methodology for the insertion and validation of a replacement component in the process control system 28. Each drawing shows the system 28 in reduced format, using numeric labels to refer to the same-number blocks of Figure 2. The components of the system 28 may, as noted above, reside on one or more digital data processing apparatus 10.
In Figure 3 A, a new or replacement component 30a is added to system 28, e.g., to the same digital data processor as resides component 30 which it (component 30a) will replace. In the illustrated embodiment, in which component 30a comprises an OOP object, an OOP class definition comprising an object template and methods is transmitted from the server 16 to a workstation 11, e.g., as part of a contracted-for maintenance transaction, upgrade transaction, or e-commerce transaction. There, an operator or engineer instantiates a replacement object 30a from the new class and configures the object for use in controlling process 12 via controller 10. Once configured, the object is downloaded to the controller, where it replaces a prior object 30 as described in further detail below.
Those skilled in the art will appreciate that the replacement object may be downloaded to digital data processor 10 via other mechanisms, as well. Thus, for example, the object definition or preconfigured object may be downloaded directly from server 16 to the digital data processor 10. Moreover, in embodiments that utilize non-OOP constructs, alternate data structures or code constructs (e.g., DDL files) may be downloaded to processor 10 directly or via workstation 11.
Referring back to Figure 1 , depicted there are steps of an e-commerce transaction through which such a download can be effected. In step 1. an operator utilizes workstation 11 to send an inquiry to site server 16. This step, as well as the others required for installation and validation of the component 30a, preferably occur while the process control system 28 is online and operational, e.g., controlling process 12, and without substantive disruption or delay of any of the monitor and/or control functions performed by the replaced component, or of any components in communication therewith. As used herein, "substantive disruption or delay" refers to any disruption or delay having more than negligible impact on the aforesaid monitor and/or control functions.
In step 2, the site server 16 responds with information regarding possible upgrades. The server 16 can provide a complete listing of available upgrades or, alternatively, only those applicable to process control system 28.
In step 3. the operator selects a desired upgrade (e.g., the class for component 30a) and provides requisite purchase account information, e.g., credit card, PO number, etc. The operator also supplies whatever additional information is required or desirable in order to effect the download from the server 16. In step 4, the site server 16 downloads the replacement software to workstation 11, e.g.. in the form of a .Java file, a .class file, a DLL file (e.g., for non-OOP implementations), or in any other format suitable for adding software aspects of component 30a to workstation 11.
In step 5, workstation 11 instantiates and configures component 30a, based on the new class, to be similar to component 30 and downloads it for testing in the control processor 10.
Those skilled in the art will, of course, appreciate that numerous other alternatives may be employed to add the class for component 30a (or, e.g., in non-object oriented systems, to add the component 30a, itself) to digital data processor 10. These include, for example, installing the component from a CDROM, diskette, or other medium. By way of further example, electronic downloading of the component 30a can be "requested" by the system 28, itself. For example, the component 30 being replaced can itself query the site server 16 for upgrades, e.g., periodically, upon expiration of an obsolescence timer, in response to messaging from site server 12, or otherwise.
Turning to Figure 3B, the downloaded component 30a is coupled to the sources of the block 30a that it is intended to replace, i.e., block 30. In a preferred embodiment, the component is downloaded in the form of a JAVA ".class" file and, hence, it is immediately operational for purposes for such coupling. In other embodiments, additional steps (such as compilation, linking/loading, etc.) required to bring component 30a into existence on digital data processor 10 and/or to make it available for coupling into control system 28 can be effected at this time.
The manner in which component 30a is coupled to the sources of component 30 varies in accord with the manner in which source information is stored in process control system 28. For example, if pointers to sources for component 30 are maintained in its own stores, component 30a can copy that information. Alternatively, if source information is coded into component 30 via a configurator (not shown), such a configurator may be employed to imbue component 30a with the same information. In addition to such "source coupling," the outputs of blocks 30 and 30a are routed to a comparator (labeled "=") so that they can be compared. This can reside within supervisor object 29, within components 30, 30a themselves, within workstation 11, or elsewhere within the system 28. Routing can be effected by adding additional sinks to blocks 30, 30a, i.e., by defining them as sources for the comparator, or otherwise. Apart from routing its outputs to the comparator, replacement object 30a is temporarily prevented from applying those outputs to other components, e.g., 29, 32, in the system.
Once coupled as described above, the potential replacement block 30a is tested to determine whether its output is comparable with that of the block 30. To this end, block 30a processes inputs received identically with block 30 and generates output comparable with that of block 30. Comparison can be performed in any manner known in the art, preferably, using comparison methodologies defined in the newly instantiated object 30a, in the original block 30, or elsewhere in the system. In the illustrated embodiment, graphical or other output indicative of the comparison is generated by the comparator for routing to a log and or to the operator workstation 11.
If the results of the comparison are acceptable, and if the operator signals his or her confirmation, installation of the replacement module is completed as shown in Figure 3C. This is effected by further modification of the centralized or distributed source/sink stores so that component 30a is identified as the source or sink of any component 29, 32 for which component 30 was previously so identified. Information regarding component 30 can then be removed from those stores. As with the preceding steps, this too preferably occurs while the process control system 28 is operational so as "not to miss a beat."
In one embodiment, the foregoing operations are effected by executing sequences of the type that follow on the workstation 11 and control processor 10:
Workstation 1. Obtain new composite, block, or part class from server 16.
2. Instantiate new object 30a from class.
3. Instantiate all external bi-directional (cascade) input variables.
4. Configure new object 30a to handle tasks of object it is to replace:
Connect forward parameter of all cascade inputs and connect variable of all uni-directional inputs to source of inputs of old object.
Connect back parameter of all cascade outputs to back parameter of existing outputs .
Create a sinkList object for the list of output sinks of object 30 being replaced.
Create test runList object.
Create final runList object.
5. Serialize new object 30a, sinkList object, test runList object, and final runList object to an object file for each.
Control Processor 1. Download new class files.
2. Download new object 30a and new test runList object file.
3. Send message with object names.
4. Set flag in application to instantiate new object 30a from the new class.
5. Read object file to customize object. 6. Replace existing runList with new runList from runList object file.
7. Continue executing runList.
8. Bring output of old and new objects to display with trends.
9. Let operator experiment by creating transients.
10. If new object performs satisfactorily, the operator pushes the "accept" button. 11. Download sinkList object for the list of output sinks of original object 30 and make new output connections in sink objects.
12. Disconnect (null) inputs in old object 30.
13. Download final runList and continue execution.
14. Change cascade input from forward parameter to variable. 15. Delete (null) old object 30 and object files.
Described above are methods and apparatus achieving the desired objects. Those slcilled in the art will appreciate that the embodiments described herein and shown in the drawings are examples of the invention and that other embodiments incorporating one or more of the mechanisms and techniques herein, or equivalents thereof, fall within the scope of the invention. Thus, for example, further embodiments of the invention provide environmental control systems utilizing apparatus and methods like those herein to monitor and/or control heating, ventilation, cooling, and other environmental factors. Yet still further embodiments of the invention provide industrial control systems, manufacturing control systems, or the like, that also utilize apparatus and methods like those herein to monitor and/or control respective industrial, manufacturing or other processes.
By way of further non-limiting example, it will be appreciated that the comparison phase can involve matching the output of potential replacement object 30a with a standard other than the output of object 30.
By way of still further non-limiting example, it will be appreciated that replacement components can be downloaded directly to a controller or other digital data processing apparatus in which thev are to be executed.
In view of the foregoing, what is claimed is:

Claims

1. A control system, including
a first component and a second component, the first component being coupled to and transferring information with a third component, and
at least a selected one of the first and second components selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
2. A control system according to claim 1, wherein the control system remains operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
3. A control system according to claim 1, wherein the second component generates information for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
4. A control system according to claim 3, comprising a comparator that is coupled with the first and second components and that compares the information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
5. A control system according to claim 4, wherein the comparator is coupled to an operator console and wherein the comparator applies thereto an output indicative of the results of the comparison.
6. A control system according to claim 4, wherein the comparator is resident in any of the first component, second component, third component, an operator workstation, elsewhere in the control system.
7. A control system according to claim 4, wherein the selected component selectively decouples the first and third components from information transfer and couples the second and third components for information transfer in response to any of an operator command and a result of the comparison.
8. A control system according to claim 1, comprising one or more stores identifying any of sources and sinks of information transferred between the components.
9. A control system according to claim 8, wherein the one or more stores are any of centralized and distributed within the control system.
10. A control system according to claim 9, wherein the one or more stores comprise any of pointers, symbols, variables, matrices, arrays, tables, records, databases, and files.
11. A control system according to claim 8, wherein at least one of the first and second components updates one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
12. A control system, including
a first component coupled to and transferring information with a third component, at least the first component being resident on a first digital data processor,
a second digital data processor coupled with the first digital data processor,
the second digital data processor transferring any of a second component and a definition thereof to the first digital data processor,
at least a selected one of the first and second components selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
13. A control system according to claim 12, wherein the control system remains operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
14. A control system according to claim 12, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor in response to a request from an operator.
15. A control system according to claim 12, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor as part of any of a contracted-for maintenance transaction, an upgrade transaction and an e-commerce transaction.
16. A control system according to claim 12, wherein the second component generates information for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
17. A control system according to claim 16, comprising a comparator that is coupled with the first and second components and that compares the information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
18. A control system according to claim 17, wherein the selected component selectively decouples the first and third components from information transfer and couples the second and third components for information transfer in response to any of an operator command and a result of the comparison.
19. A control system according to claim 12, comprising one or more stores identifying any of sources and sinks of information transferred between the components.
20. A control system according to claim 19, wherein at least one of the first and second components updates one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
21. A control system that controls any of a manufacturing, industrial, and environmental control process, the control system including
a first component and a second component, the first component being coupled to and transferring information with a third component,
at least one of the first and third components being arranged for at least one of monitoring and controlling said manufacturing, industrial, and environmental control process,
at least a selected one of the first and second components selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
22. A control system according to claim 21, wherein the control system remains operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
23. A control system according to claim 21 , wherein at least one of the first and third components is directly or indirectly coupled to a device that at least one of monitors and controls said manufacturing, industrial, and environmental control process.
24. A control system according to claim 21, wherein the second component generates information for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
25. A control system according to claim 24, comprising a comparator that is coupled with the first and second components and that compares the information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
26. A control system according to claim 25, wherein the comparator is coupled to an operator console and wherein the comparator applies thereto an output indicative of the results of the comparison.
27. A control system according to claim 25, wherein the comparator is resident in any of first component, second component, third component, an operator workstation, elsewhere in the control system.
28. A control system according to claim 25, wherein the selected component selectively decouples the first and third components from information transfer and couples the second and third components for information transfer in response to any of an operator command and a result of the comparison.
29. A control system according to claim 21, comprising one or more stores identifying any of sources and sinks of information transferred between the components.
30. A control system according to claim 29, wherein the one or more stores are any of centralized and distributed within the control system.
31. A control system according to claim 30, wherein the one or more stores comprise any of pointers, symbols, variables, matrices, arrays, tables, records, databases, and files.
32. A control system according to claim 29, wherein at least one of the first and second components updates one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
33. A control system that controls any of a manufacturing, industrial, and environmental control process, the control system including,
a first component coupled to and transferring information with a third component, at least the first component being resident on a first digital data processor,
at least one of the first and third components being arranged for at least one of monitoring and controlling said manufacturing, industrial, and environmental control process,
a second digital data processor coupled with the first digital data processor,
the second digital data processor transferring any of a second component and a definition thereof to the first digital data processor,
at least a selected one of the first and second components selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
34. A control system according to claim 33, wherein the control system remains operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
35. A control system according to claim 33, wherein at least one of the first and third components is directly or indirectly coupled to a device that at least one of monitors and controls said manufacturing, industrial, and environmental control process.
36. A control system according to claim 33, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor in response to a request from an operator.
37. A control system according to claim 33, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor as part of any of a contracted-for maintenance transaction, an upgrade transaction and an e-commerce transaction.
38. A control system according to claim 33, wherein the second component generates information for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
39. A control system according to claim 38. comprising a comparator that is coupled with the first and second components and that compares the information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
40. A control system according to claim 39, wherein the selected component selectively decouples the first and third components from information transfer and couples the second and third components for information transfer in response to any of an operator command and a result of the comparison.
41. A control system according to claim 33, comprising one or more stores identifying any of sources and sinks of information transferred between the components.
42. A control system according to claim 41, wherein at least one of the first and second components updates one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
43. A method of operating a control system of the type having a first component that is coupled to and that transfers information with a third component, the method comprising
providing a second component,
selectively operating any of the first and second components to decouple the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
44. A method according to claim 43, including the step of keeping the control system operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
45. A method of operating a control system according to claim 43. comprising generating information with the second component for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
46. A method of operating a control system according to claim 45, comprising comparing information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
47. A method of operating a control system according to claim 46, comprising applying to an operator console an output indicative of the results of the comparison.
48. A method of operating a control system according to claim 46, comprising responding to any of an operator command and a result of the comparing step by selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second and third components for information transfer.
49. A method of operating a control system according to claim 43, comprising providing one or more stores identifying any of sources and sinks of information transferred between the components.
50. A method of operating a control system according to claim 49, comprising updating one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
51. A method of operating a control system of the type having
a first component coupled to and transferring information with a third component, at least the first component being resident on a first digital data processor,
the method comprising
transferring, from a second digital data processor to the first digital data processor, any of a second component and a definition thereof,
operating any of the first and second components to selectively decoupling the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of infoπnation therewith.
52. A method according to claim 51, including the step of keeping the control system operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
53. A method of operating a control system according to claim 51, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor in response to a request from an operator.
54. A method of operating a control system according to claim 51 , wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor as part of any of a contracted-for maintenance transaction, an upgrade transaction and an e-commerce transaction.
55. A method of operating a control system according to claim 51 , generating information with the second component for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
56. A method of operating a control system according to claim 55, comprising comparing information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
57. A method of operating a control system according to claim 56, comprising responding to any of an operator command and a result of the comparing step by selectively decoupling the first and third components from information transfer and coupling the second and third components for information transfer.
58. A method of operating a control system according to claim 57, comprising providing one or more stores identifying any of sources and sinks of information transferred between the components.
59. A method of operating a control system according to claim 58, comprising updating one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for infoπnation transfer.
60. A method of operating a control system that controls any of a manufacturing, industrial, and environmental control process, the control system including
a first component that is coupled to and that transfers information with a third component,
at least one of the first and third components being arranged for at least one of monitoring and controlling said manufacturing, industrial, and environmental control process,
the method comprising
providing a second component,
operating of any of the first and second components to selectively decouple the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of information therewith.
61. A method according to claim 60, including the step of keeping the control system operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
62. A method of operating a control system according to claim 60, wherein at least one of the first and third components is directly or indirectly coupled to a device that at least one of monitors and controls said manufacturing, industrial, and environmental control process.
63. A method of operating a control system according to claim 60, generating information with the second component for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
64. A method of operating a control system according to claim 63, comprising comparing information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
65. A method of operating a control system according to claim 64, comprising applying to an operator console an output indicative of the results of the comparison.
66. A method of operating a control system according to claim 64, comprising responding to any of an operator command and a result of the comparing step by selectively decoupling the first and third components from information transfer and coupling the second and third components for information transfer.
67. A method of operating a control system according to claim 60, comprising providing one or more stores identifying any of sources and sinks of information transfeπed between the components.
68. A method of operating a control system according to claim 60, comprising updating one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
69. A method of operating a control system that controls any of a manufacturing, industrial, and environmental control process, the control system including
a first component coupled to and transfeπing information with a third component, at least the first component being resident on a first digital data processor,
at least one of the first and third components being aπanged for at least one of monitoring and controlling said manufacturing, industrial, and environmental control process,
the method including
transferring, from a second digital data processor to the first digital data processor, any of a second component and a definition thereof,
operating any of the first and second components to selectively decouple the first and third components from information transfer and, in lieu thereof, coupling the second component to the third component for transfer of infoπnation therewith.
70. A method according to claim 69, including the step of keeping the control system operational while the first and third components are decoupled from information transfer and wherein the second and third components are coupled for information transfer.
71. A method of operating a control system according to claim 69, wherein at least one of the first and third components is directly or indirectly coupled to a device that at least one of monitors and controls said manufacturing, industrial, and environmental control process.
72. A method of operating a control system according to claim 69, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor in response to a request from an operator.
73. A method of operating a control system according to claim 69, wherein the second digital data processor transfers any of the second component and the definition thereof to the first digital data processor as part of any of a contracted-for maintenance transaction, an upgrade transaction and an e-commerce transaction.
74. A method of operating a control system according to claim 69, generating information with the second component for possible transfer to the third component, which information is comparable with information generated by the first component for transfer to such third component.
75. A method of operating a control system according to claim 74, comprising comparing information generated by the first component for transfer to such third component with information generated by the second component for possible transfer to the third component.
76. A method of operating a control system according to claim 75, comprising responding to any of an operator command and a result of the comparing step by selectively decoupling the first and third components from information transfer and coupling the second and third components for information transfer.
77. A method of operating a control system according to claim 69, comprising providing one or more stores identifying any of sources and sinks of information transfeπed between the components.
78. A method of operating a control system according to claim 69, comprising updating one or more of the stores in order to decouple the first and third components from information transfer and in order to couple the second and third components for information transfer.
79. A method of electronic commerce comprising
transferring, from a first digital data processor to a second digital data processor, any of a first control system component and a definition thereof,
the first control system component being adapted for use in a control system of the type having a second control system component coupled to and transfeπing infoπnation with a third component,
any of the first and second control system components being further adapted for selectively decoupling the second and third components from information transfer and, in lieu thereof, coupling the first control component to the third component for transfer of information therewith
80. A method according to claim 79, comprising transfeπing the first control system component from the first digital data processor to the second digital data processor as part of any of a contracted-for maintenance transaction, an upgrade transaction and an e-commerce transaction.
81. A method according to claim 79, comprising transfeπing the first control system component from the first digital data processor to the second digital data processor in response to an operator request.
82. A method according to claim 79, comprising transferring the first control system component from the first digital data processor to the second digital data processor in response to a request by the second control component. A method according to claim 79, wherein at least the second control component is resident on the second digital data processor.
PCT/US2000/016152 1999-06-11 2000-06-09 Control system with improved installation WO2000077583A1 (en)

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