CN115480549A - Apparatus and method for communicatively coupling field devices to a controller in a process control system - Google Patents

Abstract

The present invention relates to apparatus and methods to communicatively couple field devices to controllers in a process control system. A disclosed example apparatus includes a first interface communicatively coupled to one of a first field device or a second field device. The first interface communicates using a first fieldbus communication protocol when coupled to a first field device and communicates using a second fieldbus communication protocol when coupled to a second field device. An example apparatus includes a communication processor to encode first information received from the one of the first or second field devices for communication via a bus using a third communication protocol. The example apparatus includes a second interface communicatively coupled to the communication processor and the bus to communicate first information to a controller in the process control system. The bus communicates second information received from the other of the first field device or the second field device using a third communication protocol.

Description

Means for communicatively coupling field devices to a controller in a process control system and method

This application is a divisional application of a patent application with application number 201610009263.8 and titled "Apparatus and method for communicatively coupling field devices to controllers in a process control system" filed on January 7, 2016.

technical field

The present disclosure relates generally to process control systems and, more particularly, to apparatus and methods for communicatively coupling field devices to controllers in process control systems.

Background technique

Process control systems, such as those used in chemical, petroleum, pharmaceutical, pulp and paper, or other manufacturing processes, typically include one or more process controllers communicatively coupled to At least one host computer including at least one operator workstation and communicatively coupled to one or more field devices configured to communicate via analog, digital, or combined analog/digital communication protocols. Field devices can be, for example, device controllers, valves, valve actuators, valve positioners, switches, and transmitters (e.g., temperature, pressure, flow rate, and chemical composition sensors), or combinations thereof, that perform functions within a process control system, Examples include opening or closing valves, and measuring or inferring process parameters. Process controllers receive signals representing process measurements made by field devices and/or other information about field devices, use this information to implement control routines, and generate control signals that are communicated over a bus or other Lines are sent to field devices to control the operation of the process control system.

A process control system may include multiple field devices that provide several different functional capabilities and often use point-to-point two-wire interfaces (e.g., one field device communicatively coupled to a field device bus) or multidrop ( For example, a plurality of field devices are communicatively coupled to a field device bus) line connection arrangement or communicatively coupled to a process controller by means of wireless communication. Some field devices are configured to operate using relatively simple commands and/or communications (eg, ON commands and OFF commands). Other field devices are more complex, requiring more commands and/or more communication information, which may or may not include simple commands. For example, more complex field devices may communicate analog values with digital communications superimposed on the analog values using, for example, Highway Addressable Remote Transducer ("HART") communication protocols. Other field devices may use all-digital communications (eg, FOUNDATION fieldbus communication protocol).

In a process control system, each field device is typically coupled to a process controller via one or more I/O cards and a corresponding communication medium (eg, two-wire cable, wireless link, or fiber optics). Thus, multiple communication media are required to communicatively couple multiple field devices to the process controller. Multiple communication media coupled to field devices are often routed through one or more field junction boxes, at which point the multiple communication media are coupled to corresponding communication media (e.g., corresponding two-wire conductors) of a multi-conductor cable, the multiple communication media Core cables are used to communicatively couple field devices to a process controller via one or more I/O cards.

Contents of the invention

Exemplary apparatus and methods for communicatively coupling field devices to a controller in a process control system are described. According to an example, an exemplary apparatus includes a base and a module movably attached to the base. The base includes a first physical interface communicatively coupled to one of a first field device in the process control system or a second field device in the process control system, and a second physical interface, the first physical interface Two physical interfaces are communicatively coupled to a controller in the process control system via the bus. When the first physical interface is communicatively coupled to the first field device, the module communicates with the first field device using a first communication protocol. When the first physical interface is communicatively coupled to the second field device, the module communicates with the second field device using the second communication protocol. The modules communicate with the controller via the bus using a third communication protocol. The third communication protocol is different from the first communication protocol and the second communication protocol.

According to another example, an exemplary method includes receiving first information at a base having a first physical interface communicatively coupled to a first field device or a process control system in a process control system. One of the second field devices in the system. The exemplary method also includes encoding first information at the module removably attached to the base for communication using a first communication protocol. When the first physical interface is coupled to the first field device, first information is communicated from the first field device to the module using a second communication protocol. When the first physical interface is coupled to the second field device, the first information is communicated from the second field device to the module using a third communication protocol. The third communication protocol is different from the first communication protocol and the second communication protocol. The method also includes communicating the encoded first information from the module to the controller via the second physical interface of the base via the bus using the first communication protocol.

According to yet another example, an exemplary apparatus includes a first interface communicatively coupled to one of a first field device in a process control system or a second field device in the process control system. The first interface communicates using a first Fieldbus communication protocol when coupled to the first field device, and communicates using a second Fieldbus communication protocol when coupled to the second field device. An exemplary apparatus includes a communications processor communicatively coupled to the first interface. The communications processor encodes first information received from one of the first field device or the second field device for communication via a third communication protocol different from the first fieldbus communication protocol and the second fieldbus communication protocol. Protocol bus for communication. The exemplary apparatus includes a second interface communicatively coupled to the communications processor and the bus for communicating the first information to a controller in the process control system via the bus using a third communications protocol. The bus communicates second information received from the other of the first field device or the second field device using a third communication protocol.

Description of drawings

FIG. 1A is a block diagram illustrating an example process control system.

1B-1D illustrate alternative exemplary embodiments that may be used to communicatively couple workstations, controllers, and I/O cards.

FIG. 2 is a detailed illustration of the exemplary marshalling cabinet of FIG. 1A.

FIG. 3 is another example marshalling cabinet that may be used to implement the example marshalling cabinet of FIG. 1A .

FIG. 4 shows a top view of the example termination module of FIGS. 1A and 2 , and FIG. 5 shows a side view of the example termination module of FIGS. 1A and 2 .

6 is a detailed block diagram of the exemplary termination module of FIGS. 1A, 2, 4, 5, 13A-B, and 14A-B.

7 is a detailed block diagram of the exemplary I/O card of FIG. 1A.

8 is an illustration of an exemplary labeler associated with the termination modules of FIGS. 1A, 2-6, 13A-B, and 14A-B that can be used to display field device identification information and/or any other field device information. Detailed block diagram.

9 illustrates an isolation circuit configuration that may be implemented in conjunction with the exemplary termination modules of FIG. 1A to electrically isolate the termination modules from each other, from field devices, and from a communication bus.

10A and 10B illustrate flow diagrams of exemplary methods that may be used to implement the termination modules of FIGS. transfer information between cards.

11A and 11B illustrate flowcharts of exemplary methods that may be used to implement the I/O card of FIG. 1A to communicate information between a termination module and a workstation.

12 is a flowchart of an exemplary method that may be used to implement the taggers of FIGS. 2, 3, 6, and 8 to retrieve and display information associated with a field device communicatively coupled to a termination module .

13A and 13B are block diagrams illustrating another example process control system before and after implementing the teachings disclosed herein with respect to an example Profibus PA process area and an example FOUNDATION Fieldbus H1 (FF-H1 ) process area.

14A and 14B illustrate an alternative exemplary embodiment of peer-to-peer communication of two FF-H1 compliant field devices communicatively coupled to corresponding termination modules.

15 is a flowchart of an exemplary method that may be used to implement the termination modules of FIGS. The communication protocol associated with the device.

16 is a block diagram of an example processor system that may be used to implement the example systems and methods described herein.

detailed description

Although the following describes exemplary apparatuses and systems comprising, among other components, software and/or firmware executing on hardware, it should be noted that such systems are merely exemplary and should not be considered is restrictive. For example, it is contemplated that any or all of these hardware, software, and firmware components may be embodied exclusively in hardware, exclusively in software, or in any combination of hardware and software. Thus, while exemplary devices and systems are described below, those of ordinary skill in the art will readily appreciate that the examples provided are not the only ways to implement such devices and systems.

An exemplary process control system includes a control room (e.g., control room 108 of FIG. 1A ), a process controller area (e.g., process controller area 110 of FIG. 1A ), a termination area (e.g., termination area 140 of FIG. 1A ). , and one or more process areas (eg, process area 114 and process area 118 of FIG. 1A ). A process area includes a plurality of field devices that perform operations (e.g., control valves, control motors, control boiler, monitoring, measuring parameters, etc.). Some process areas are inaccessible to humans due to harsh environmental conditions (eg, relatively high temperatures, airborne toxins, unsafe radiation levels, etc.). A control room typically includes one or more workstations within an environment that can be safely accessed by humans. Workstations include user applications that users (eg, engineers, operators, etc.) can access to control the operation of the process control system, eg, by changing variable values, process control functions, and the like. The process control area includes one or more controllers communicatively coupled to workstations in the control room. The controller automates the control of the field devices in the process area by executing the process control strategies implemented via the workstations. An exemplary process strategy includes measuring pressure using a pressure sensor field device and automatically sending a command to a valve positioner to open or close a flow valve based on the pressure measurement. The termination area includes marshalling cabinets that enable controllers to communicate with field devices in the process area. Specifically, the marshalling cabinet includes a plurality of termination modules for grouping, organizing or routing signals from the field devices to one or more I/O cards communicatively coupled to the controller. The I/O card converts information received from field devices into a format compatible with the controller, and converts information from the controller into a format compatible with the field devices.

Known techniques for communicatively coupling field devices within a process control system to a controller include connecting each field device to a corresponding I/O device communicatively coupled to the controller (e.g., process controller, programmable logic controller, etc.). A separate bus (eg, wire, cable, or circuit) is used between O cards. I/O cards enable communicative coupling of a controller to multiple field devices that communicate with different data types or signal types (e.g., analog Input (AI) data type, analog output (AO) data type, discrete input (DI) data type, discrete output (DO) data type, digital input data type, and digital output data type) are associated with different field device communication protocols . For example, an I/O card may be provided with one or more field device interfaces configured to exchange information with the field device using a field device communication protocol associated with the field device. Different field devices interface via different channel types (for example, analog input (AI) channel type, analog output (AO) channel type, discrete input (DI) channel type, discrete output (DO) channel type, digital input channel type, and digital output channel type) to communicate. Additionally, I/O cards can transform information received from field devices (eg, voltage levels) into information that the controller can use to perform operations associated with controlling the field devices (eg, pressure measurements). Known techniques require a bundle of wires or bus (eg, a multiconductor cable) to communicatively couple multiple field devices to an I/O card. Unlike known techniques that use a separate bus to communicatively couple each field device to an I/O card, the exemplary apparatus and methods described herein can be used to field devices and use a bus (e.g., conductive communication medium, optical communication medium, wireless communication medium) communicatively coupled between the termination panel and the I/O card to communicatively couple the field device to the I/O card ) to communicatively couple the field device to the I/O card.

The exemplary apparatus and methods described herein include the use of an exemplary general-purpose I/O bus (e.g., a common or shared communication bus) that communicatively couples one or more termination modules to one or more Multiple I/O cards. Each termination module is communicatively coupled to one or more corresponding field devices using a corresponding field device bus (eg, an analog bus or a digital bus). The termination module is configured to receive field device information from the field devices via the field device bus, and to communicate via the general purpose I/O bus by, for example, packaging the field device information and transmitting the packaged information to the I/O card via the general purpose I/O bus. The bus transfers field device information to the I/O cards. Field device information may include, for example, field device identification information (e.g., device tag, electronic serial number, etc.), field device status information (e.g., communication status, diagnostic health information (open loop, short circuit, etc.)), field device activity information (e.g., , process variable (PV) value), field device description information (for example, field device type or function, such as valve actuator, temperature sensor, pressure sensor, flow sensor, etc.), field device connection configuration information (for example, multipoint branch bus connection, point-to-point connection, etc.), field device bus or segment identification information (e.g., the field device bus or field device segment via which the field device is communicatively coupled to the termination module), and/or the field device Data type information (eg, a data type descriptor representing the data type used by a particular field device). The I/O card can extract field device information received via the Universal I/O bus and communicate the field device information to the controller, which can then communicate some or all of the information to one or more workstation terminals for subsequent analyze.

In order to transfer field device information (e.g., commands, instructions, queries, threshold activity values (e.g., threshold PV values), etc.) Device information is passed to multiple termination modules. Each of the termination modules can then extract or unpack the corresponding field device information from the packetized communication received from the corresponding I/O card and transmit the field device information to the corresponding field device.

In the illustrated examples described herein, a termination panel (e.g., marshalling cabinet) is configured to receive (e.g., connect to) a plurality of termination modules, each of which is communicatively coupled to a different field device . In order to indicate at the terminating modules which terminating modules are connected to which field devices, a terminating label (or marking system) is provided for each terminating module. A termination labeler includes an electronic display (eg, a liquid crystal display (LCD)) and components to determine which field device or devices are connected to a termination module corresponding to the termination labeler. In some exemplary embodiments, a display is mounted on a termination panel instead of a termination module. Each of the displays is mounted in association with a respective terminating modular jack. In this way, when a termination module is removed from the termination panel, a corresponding display remains on the termination panel for use by a subsequently connected termination module.

Turning now to FIG. 1A , an exemplary process control system 100 includes a workstation 102 communicatively coupled to a controller 104 via a bus or local area network (LAN) 106 , commonly referred to as an application control network (ACN). LAN 106 may be implemented using any desired communications media and protocols. For example, LAN 106 may be based on a hardwired or wireless Ethernet communication protocol. However, any other suitable wired or wireless communication medium and protocol may be used. Workstation 102 may be configured to perform operations associated with one or more information technology applications, user interaction applications, and/or communication applications. For example, workstation 102 may be configured to perform operations associated with applications related to process control and communication applications that enable workstation 102 and controller 104 to use any desired communication medium (e.g., wireless, hardwired, etc.) ) and protocols (such as HTTP, SOAP, etc.) to communicate with other devices or systems. Controller 104 may be configured to execute one or more process control routines or functions generated by a system engineer or other system operator using, for example, workstation 102 or any other workstation, and Downloaded to and instantiated in the controller 104 . In the example shown, the workstation 102 is located in a control room 108 and the controller 104 is located in a process controller area 110 separate from the control room 108 .

In the example shown, the example process control system 100 includes field devices 112a - c in a first process area 114 and field devices 116a - c in a second process control area 118 . To communicate information between the controller 104 and the field devices 112a-c and 116a-c, the exemplary process control system 100 is provided with field junction boxes (FJB) 120a-b and marshalling cabinets 122. Each of field junction boxes 120a - b routes signals from a corresponding one of field devices 112a - c and 116a - c to marshalling cabinet 122 . Marshalling cabinet 122 in turn marshals (e.g., organizes, packs, etc.) the information received from field devices 112a-c and 116a-c and routes the field device information to corresponding I/O cards (e.g., I/O cards 132a-b and 134a-b). In the example shown, communication between the controller 104 and the field devices 112a-c and 116a-c is bidirectional such that the marshalling cabinet 122 is also used to connect Information received by the I/O cards is routed to corresponding ones of field devices 112a-c and 116a-c.

In the example shown, field devices 112a-c are communicatively coupled to field junction box 120a and field devices 116a-c are communicatively coupled to field junction box 120b via conductive, wireless, and/or optical communication media. For example, field junction boxes 120a-b may be provided with one or more electrical, wireless, and/or optical data transceivers for communicating with electrical, wireless, and/or optical data transceivers of field devices 112a-c and 116a-c. communication. In the example shown, field junction box 120b is communicatively wirelessly coupled to field device 116c. In an alternative exemplary embodiment, marshalling cabinet 122 may be omitted, and signals from field devices 112a - c and 116a - c may be routed from field junction boxes 120a - b directly to the I/O cards of controller 104 . In yet another exemplary embodiment, the field junction boxes 120a - b may be omitted, and the field devices 112a - c and 116a - c may be connected directly to the marshalling cabinet 122 .

The field devices 112a-c and 116a-c may be fieldbus-compliant valves, actuators, sensors, etc., in which case the field devices 112a-c and 116a-c communicate via the well-known FOUNDATION fieldbus communication protocol (e.g., FF-H1 ) digital data bus for communication. Of course, other types of field devices and communication protocols could be used instead. For example, field devices 112a-c and 116a-c may instead be Profibus (eg, Profibus PA), HART, or AS-i compliant devices that communicate via a data bus using the well-known Profibus and HART communication protocols. In some example implementations, the field devices 112a-c and 116a-c may communicate information using analog or discrete communications rather than digital communications. Additionally, communication protocols may be used to communicate information associated with different data types.

Each of the field devices 112a-c and 116a-c is configured to store field device identification information. The field device identification information may be a physical device tag (PDT) value, device tag name, electronic serial number, etc. that uniquely identifies each of the field devices 112a-c and 116a-c. In the illustrated example of FIG. 1A, field devices 112a-c store field device identification information in the form of physical device tag values PDT0-PDT2, and field devices 116a-c store field device identification information in the form of physical device tag values PDT3-PDT5. The field device identification information may be stored or programmed into the field devices 112a-c and 116a-c by the field device manufacturer and/or by operators or engineers involved in the installation of the field devices 112a-c and 116a-c.

To route information associated with the field devices 112a-c and 116a-c within the marshalling cabinet 122, the marshalling cabinet 122 is provided with a plurality of termination modules 124a-c and 126a-c. Termination modules 124a-c are configured to group information associated with field devices 112a-c in first process area 114, and termination modules 126a-c are configured to group information associated with field devices 116a in second process area 118 -c associated information. As shown, termination modules 124a-c and 126a-c are communicatively coupled to field junction boxes 120a-b via respective multi-conductor cables 128a and 128b (eg, multi-bus cables). In an alternate exemplary embodiment in which marshalling cabinet 122 is omitted, termination modules 124a-c and 126a-c may be installed in respective ones of field junction boxes 120a-b.

The illustrated example of FIG. 1A shows a point-to-point configuration in which each wire or pair of wires (e.g., bus, twisted-pair communication medium, two-wire communication medium, etc.) Information uniquely associated with a respective one of devices 112a-c and 116a-c. For example, the multiconductor cable 128a includes a first conductor 130a, a second conductor 130b, and a third conductor 130c. Specifically, the first wire 130a is used to constitute a first data bus configured to transmit information between the termination module 124a and the field device 112a, and the second wire 130b is used to constitute a first data bus configured to transmit information between the termination module 124b and the field device 112a. The second data bus for communicating information between the devices 112b, and the third wire 130c are used to form a third data bus configured to communicate information between the termination module 124c and the field device 112c. In an alternative exemplary embodiment using a multi-drop wiring structure, each of the termination modules 124a-c and 126a-c are communicatively coupled with one or more field devices. For example, in a multi-drop configuration, termination module 124a may be communicatively coupled to field device 112a and another field device (not shown) via first conductor 130a. In some exemplary embodiments, a termination module may be configured to communicate wirelessly with a plurality of field devices using a wireless mesh network.

Additionally or alternatively, in some examples, a second field device (not shown) is communicatively coupled to termination module 124a via first conductor 130a as a redundant, backup, or replacement field device in addition to field device 112a. In some such examples, termination module 124a is configured to communicate exclusively with field device 112a until needed with a backup device (e.g., when field device 112a fails, when an operator configures a backup device to replace field device 112a) until the communication takes place. That is, although there are two devices communicatively coupled to the terminating module 124a via the first wire 130a, unlike the multi-drop configuration, the communication between the terminating module 124a and the field device 112a or the backup field device actually acts as Point-to-point connection operation. Specifically, although a backup field device may be detected by termination module 124a, all communications will be directed to the primary or live device (e.g., field device 112a) until the live device fails, at which point communication with Standby field device communication (automatically or initiated by process control personnel). In some examples, while the failed field device 112a is still in the process control system (e.g., prior to physical removal and/or deletion from the system's logical structure), the backup field device is commissioned and begins communicating with the end The connection module 124a communicates. In some such examples, the spare field device retains the "spare" designation until plant personnel designate the spare field device as the new primary device. In other examples, the termination module 124a automatically swaps the field device 112a with a spare field device upon failure of the field device 112a. The ability to configure a backup field device to take over communications in this manner is typically not available for certain communications protocols (eg, HART) because individual field devices are communicatively coupled directly to the I/O card in a point-to-point fashion. As a result, replacement of a failed field device typically involves physical removal of the field device, installation of a new field device, and subsequent manual activation of the new field device. But in some disclosed examples, as more fully described below, field device 112a is indirectly connected to I/O over a high-speed general-purpose I/O bus through termination module 124a when implemented using the HART protocol for a much faster alternative. O card, the high speed general purpose I/O bus has sufficient bandwidth to manage the presence of a single spare field device on the first conductor 130a. In addition to or instead of HART, the backup field devices on the first wire 130a may also be implemented with other communication protocols (eg, Profibus PA, FF-H1, etc.).

Each of the termination modules 124a-c and 126a-c may be configured to communicate with a corresponding one of the field devices 112a-c and 116a-c using a different data type. For example, termination module 124a may include a digital field device interface for communicating with field device 112a using digital data, while termination module 124b may include an analog field device interface for using The analog data is communicated with field device 112b.

To control I/O communications between the controller 104 (and/or the workstation 102) and the field devices 112a-c and 116a-c, the controller 104 is provided with a plurality of I/O cards 132a-b and 134a-b . In the example shown, the I/O cards 132a-b are configured to control I/O communications between the controller 104 (and/or the workstation 102) and the field devices 112a-c in the first process area 114, And the I/O cards 134a - b are configured to control I/O communications between the controller 104 (and/or the workstation 102 ) and the field devices 116a - c in the second process area 118 .

In the illustrated example of FIG. 1A , I/O cards 132a - b and 134a - b are located in controller 104 . To communicate information from field devices 112a - c and 116a - c to workstation 102 , I/O cards 132a - b and 134a - b communicate the information to controller 104 , and controller 104 communicates the information to workstation 102 . Similarly, to communicate information from workstation 102 to field devices 112a-c and 116a-c, workstation 102 communicates information to controller 104, which in turn communicates information to I/O cards 132a-b and 134a-b , and I/O cards 132a-b and 134a-b transmit information to field devices 112a-c and 116a-c via termination modules 124a-c and 126a-c. In an alternative exemplary embodiment, I/O cards 132a-b and 134a-b may be communicatively coupled to LAN 106 inside controller 104 such that I/O cards 132a-b and 134a-b may communicate with workstation 102 and/or the controller 104 in direct communication.

To provide fault-tolerant operation in the event of a transmission failure of either of I/O cards 132a and 134a, I/O cards 132b and 134b are configured as redundant I/O cards. That is, if I/O card 132a fails, redundant I/O card 132b assumes control and performs the same operations that I/O card 132a would otherwise perform. Similarly, redundant I/O card 134b assumes control when I/O card 134a fails.

To enable communication between the termination modules 124a-c and the I/O cards 132a-b and between the termination modules 126a-c and the I/O cards 134a-b, the The termination modules 124a-c are communicatively coupled to the I/O cards 132a-b, and the termination modules 126a-c are communicatively coupled to the I/O cards 134a-b via a second general purpose I/O bus 136b. Unlike multiconductor cables 128a and 128b, while using separate wires or communication media for each of field devices 112a-c and 116a-c, each of universal I/O buses 136a-b is configured as Information corresponding to multiple field devices (eg, field devices 112a-c and 116a-c) is communicated using the same communication medium. For example, the communication medium may be a serial bus, a two-wire communication medium (e.g., twisted pair), optical fiber, a parallel bus, etc. Information associated with two or more field devices.

等)实施通用I/O总线136a-b中的一条或两条。In an exemplary embodiment, the general purpose I/O buses 136a-b are implemented using the RS-485 serial communication standard. The RS-485 serial communication standard can be configured to use less communication control overhead (eg, less header information) than other known communication standards (eg, Ethernet). However, in other exemplary embodiments, the universal I/O buses 136a-b may be implemented using any other suitable communications standard, including Ethernet, Universal Serial Bus (USB), IEEE 1394, and the like. Additionally, while general purpose I/O buses 136a-b are described above as being wired communication media, in other exemplary embodiments wireless communication media (eg, Wireless Ethernet, IEEE-802.11,

etc.) implement one or both of the general purpose I/O buses 136a-b.

General purpose I/O buses 136a and 136b are used to communicate information in substantially the same manner. In the example shown, I/O bus 136a is configured to communicate information between I/O cards 132a-b and termination modules 124a-c. The I/O cards 132a-b and the termination modules 124a-c use an addressing scheme to enable the I/O cards 132a-b to identify which information corresponds to which of the termination modules 124a-c, and to enable the termination modules 124a-c to Each of 124a-c is capable of determining which information corresponds to which of field devices 112a-c. When a termination module (e.g., one of the termination modules 124a-c and 126a-c) is connected to one of the I/O cards 132a-b and 134a-b, the I/O card (e.g., from the termination module ) automatically obtains the address of the termination module in order to exchange information with the termination module. In this manner, the termination modules 124a-c and 126a-c can be communicatively coupled anywhere on the respective buses 136a-b without having to manually provide termination module addresses to the I/O cards 132a-b and 134a-b, Also, it is not necessary to individually wire each of the termination modules 124a-c and 126a-c to the I/O cards 132a-b and 134a-b.

By using the universal I/O buses 136a-b, the amount of communication media (e.g., wires) required to communicate information between the marshalling cabinets 122 and the controller 104 is substantially reduced relative to known structures that require separate communications media for each termination module to communicate with the controller. Reducing the amount of communication media required to communicatively couple marshalling cabinets 122 to controller 104 (e.g., reducing the number of communication buses or communication wires) reduces design and generation of drawings for communication between controller 104 and field devices 112a-c and 116a The engineering cost required to install the connection between -c. Additionally, reducing the number of communication media in turn reduces installation and maintenance costs. For example, one of the I/O buses 136a-b replaces the multiple communication media used in known systems to communicatively couple the field devices to the controller. Thus, instead of maintaining multiple communication media for communicatively coupling field devices 112a-c and 116a-c to I/O cards 132a-b and 134a-b, the illustrated example of FIG. -b while requiring substantially less maintenance. Also, in the context of fieldbus-based field devices (e.g., Profibus PA compliant devices or FOUNDATION Fieldbus H1 (FF-H1) compliant devices), the use of the general purpose I/O buses 136a-b also reduces or eliminates the need for Costs associated with acquiring, installing and maintaining other components for implementing the associated fieldbus architecture. For example, Profibus PA and FF-H1 each typically require protocol specific I/O cards, power conditioners (for FF-H1) or DP/PA couplings in addition to cables for the trunks or segments of the fieldbus architecture device (for Profibus PA), and segment protector. However, where the Fieldbus devices coupled to the termination modules 124a-c and 126a-c communicate with the controller via the general purpose I/O bus 136a-b, such components are no longer required. Also, in some examples, where each Fieldbus device is connected to a corresponding termination module 124a-c or 126a-c in a point-to-point architecture, the cost of Fieldbus segment design effort is significantly reduced or eliminated. and complexity because the grouping of device signals is processed electronically after being received by each corresponding terminating module.

Additionally, reducing the amount of communication media required to communicatively couple marshalling cabinet 122 to I/O cards 132a-b and 134a-b results in more termination modules (e.g., termination modules 124a-c or 126a-c) More available space, thereby increasing the I/O density of the marshalling cabinet 122 relative to known systems. In the example shown in FIG. 1A , the marshalling cabinet 122 may have multiple termination modules, otherwise many more marshalling cabinets (eg, three marshalling cabinets) would be required in known system implementations. Also, in some examples, marshalling cabinet 122 may have a larger number of field devices 112a-c communicating data over a single general purpose I/O bus 136a than the number of field devices communicating data over other types of buses. A correspondingly larger number of termination modules 124a-c. For example, a Fieldbus segment is typically limited to carrying signals for up to 16 field devices. Conversely, in some examples, one of the general purpose I/O buses 136a-b may provide communications associated with up to 96 termination modules 124a-c and 126a-c.

By providing termination modules 124a-c and termination modules 126a-c (termination modules 124a-c and termination modules 126a-c may be configured to use different data type interfaces (eg, different channel types) to interface with field device 112a -c and 116a-c communicate, and it is configured to communicate with I/O cards 132a-b and 134a-b using corresponding common I/O buses 136a and 136b), the example shown in Figure 1A is in Without having to implement a plurality of different field device interface types on the I/O cards 132a-b and 134a-b, it is realized that different field device data types (such as those used by the field devices 112a-c and 116a-c) data type or channel type) is routed to I/O cards 132a-b and 134a-b. Thus, an I/O card with one interface type (e.g., an I/O bus interface type for communicating via I/O bus 136a or I/O bus 136b) can interface with multiple field devices with different field device interface types. to communicate.

Using I/O bus 136a and/or I/O bus 136b to exchange information between controller 104 and termination modules 124a-c and 126a-c enables field device-I/O card connections to be defined later in the design or installation process routing. For example, termination modules 124a-c and 126a-c may be disposed at multiple locations within marshalling cabinet 122 while maintaining access to respective ones of I/O buses 136a and 136b.

In the example shown, marshalling cabinet 122, termination modules 124a-c and 126a-c, I/O cards 132a-b and 134a-b, and controller 104 facilitate the migration of existing process control system installations to substantially similar The architecture of the exemplary process control system 100 shown in FIG. 1A. For example, since termination modules 124a-c and 126a-c are configured to include any suitable type of field device interface, termination modules 124a-c and 126a-c may be configured to communicatively couple to existing field devices. Similarly, the controller 104 may be configured to include a well-known LAN interface for communicating via a LAN to an already installed workstation. In some exemplary embodiments, I/O cards 132a-b and 134a-b may be installed in or communicatively coupled to known controllers so that it is not necessary to replace controllers already installed in the process controller system.

In the example shown, I/O card 132a includes data structure 133 and I/O card 134a includes data structure 135 . Data structure 133 stores field device identification numbers (e.g., field device identification information) corresponding to field devices (e.g., field devices 112a-c) that are assigned to communicate with I/O cards via general purpose I/O bus 136a. 132a communicates. The termination modules 124a-c may use the field device identification number stored in the data structure 133 to determine if a field device is incorrectly connected to one of the termination modules 124a-c. Data structure 135 stores field device identification numbers (e.g., field device identification information) corresponding to field devices (e.g., field devices 116a-c) that are assigned to communicate with I/O cards via general purpose I/O bus 136b. 134a communicates. Data structures 133 and 135 may be populated by engineers, operators, and/or users via workstation 102 during configuration time of example process control system 100 or during operation of example process control system 100 . In some examples, the termination modules 124a-c may be communicatively coupled to multiple field devices (eg, active field devices and redundant or standby field devices). In such an example, data structure 135 stores a field device identification number corresponding to each field device (eg, field devices 116a-c and corresponding backup field devices). Although not shown, redundant I/O card 132b stores the same data structure as data structure 133 , and redundant I/O card 134b stores the same data structure as data structure 135 . Additionally or alternatively, data structures 133 and 135 may be stored in workstation 102 .

In the illustrated example, the marshalling cabinet 122 is shown as being located in a termination area 140 separate from the process control area 110 . By using I/O buses 136a-b instead of substantially more communication media (e.g., multiple communication buses each communicating with one of field devices 112a-c and 116a-c or A finite set of them uniquely associated) to communicatively couple the termination modules 124a-c and 126a-c to the controller 104 facilitates setting the controller 104 to a smaller size than known The structure is relatively further away from the marshalling cabinet 122 . In some exemplary embodiments, process control area 110 and termination area 140 may be combined such that marshalling cabinets 122 and controllers 104 are located in the same area. In any event, locating the marshalling cabinet 122 and the controller 104 in an area separate from the process areas 114 and 118 enables the integration of the I/O cards 132a-b and 134a-b, the termination modules 124a-c and 126a-c , and general purpose I/O buses 136a-b are isolated from harsh environmental conditions (eg, heat, moisture, electromagnetic noise, etc.) that may be associated with process areas 114 and 118 . In this manner, the cost and complexity of designing and manufacturing the termination modules 124a-c and 126a-c and the I/O cards 132a-b and 134a-b can be compared to the cost and complexity of manufacturing the terminal modules 112a-c and 116a-c for the field devices 112a-c and 116a-c. The cost of communication and control circuitry is substantially reduced because termination modules 124a-c and 126a-c and I/O cards 132a-b and 134a-b do not require the necessary components to ensure reliable operation (e.g., reliable data communication). Operating specification features (eg, shielding, more robust circuitry, more sophisticated error checking, etc.) that are otherwise necessary for operation in the environmental conditions of process areas 114 and 118 .

1B-1D illustrate alternative exemplary embodiments that may be used to communicatively couple workstations, controllers, and I/O cards. For example, in the illustrated example of FIG. 1B , controller 152 (which performs substantially the same function as controller 104 of FIG. 1A ) is communicatively coupled to I/O cards 154a-b and 156a-b via backplane communication bus 158. . I/O cards 154a-b and 156a-b perform substantially the same functions as I/O cards 132a-b and 134a-b of FIG. 1A and are configured to be communicatively coupled to general purpose I/O buses 136a-b, to exchange information with the termination modules 124a-b and 126a-c. To communicate with workstation 102 , controller 152 is communicatively coupled to workstation 102 via LAN 106 .

In another illustrated example shown in FIG. 1C , a controller 162 (which performs substantially the same function as controller 104 of FIG. 1A ) is communicatively coupled via LAN 106 to workstation 102 and a plurality of I/O cards 164a. -b and 166a-b. I/O cards 164a-b and 166a-b perform substantially the same functions as I/O cards 132a-b and 134a-b of FIG. 1A and are configured to be communicatively coupled to general purpose I/O buses 136a-b, to exchange information with the termination modules 124a-c and 126a-c. But unlike I/O cards 132a-b and 134a-b of FIG. 1A and I/O cards 154a-b and 156a-b of FIG. 1B , I/O cards 164a-b and 166a-b are configured to Communicates with the controller 162 and the workstation 102 . In this manner, I/O cards 164a-b and 166a-b may exchange information with workstation 102 directly.

In yet another illustrated example shown in FIG. 1D, I/O cards 174a-b and 176a-b (which perform substantially the same functions as workstation 102 of FIG. I/O cards 132a-b and 134a-b of FIG. 1A have essentially the same function). In some exemplary embodiments, the physical I/O cards 174a-b and 176a-b are not included in the workstation 172, but the functions of the I/O cards 174a-b and 176a-b are implemented in the workstation 172. In the illustrated example of FIG. 1D , I/O cards 174a-b and 176a-b are configured to be communicatively coupled to general purpose I/O buses 136a-b to exchange information with termination modules 124a-c and 126a-c . Furthermore, in the illustrated example of FIG. ID, workstation 172 is configured to perform substantially the same functions as controller 104, such that a controller does not have to be provided to implement a process control strategy. But controllers can also be provided.

FIG. 2 is a detailed illustration of the exemplary marshalling cabinet 122 of FIG. 1A . In the example shown, the marshalling cabinet 122 is provided with receptacle rails 202a and 202b for receiving termination modules 124a-c. Additionally, the marshalling cabinet 122 is provided with an I/O bus transceiver 206 that communicatively couples the termination modules 124a-c to the general I/O bus 136a described above in connection with FIG. 1A. I/O bus transceiver 206 may be implemented using transmitter amplifiers and receiver amplifiers that condition signals exchanged between termination modules 124a-c and I/O cards 132a-b. Another general purpose I/O bus 208 is provided for marshalling cabinet 122 that communicatively couples termination modules 124 a - c to I/O bus transceiver 206 . In the example shown, I/O bus transceiver 206 is configured to communicate information using a wired communications medium. Although not shown, another I/O bus transceiver substantially similar or identical to I/O bus transceiver 206 may be provided to marshalling cabinet 122 for connecting termination module 126 a -c is communicatively coupled with I/O cards 134a-b.

Using a common communication interface (e.g., I/O bus 208 and I/O bus 136a) to exchange information between I/O cards 132a-b and termination modules 124a-c enables the definition of field devices to be defined later in the design or installation process. Connection routing for I/O cards. For example, termination modules 124a-c may be communicatively coupled to I/O bus 208 at multiple locations within marshalling cabinet 122 (eg, multiple termination module jacks of jack rails 202a-b). In addition, a common communication interface (e.g., I/O bus 208 and I/O bus 136a) between I/O cards 132a-b and termination modules 124a-c reduces communication between I/O cards 132a-b and termination modules 124a-c. The number of communication mediums (for example, the number of communication buses and/or wires) between the termination modules 124a-c, thus compared to the number of known termination modules that can be installed in the known marshalling cabinet structure, it is achieved in the marshalling cabinet Relatively more termination modules 124a-c (and/or termination modules 126a-c) are installed in 122 .

To display field device identification information and/or other field device information associated with termination modules 124a-c, a display 212 (eg, an electronic termination label) is provided for each of the termination modules 124a-c. Display 212 of termination module 124a displays a field device identification (eg, a field device tag) of field device 112a (FIG. 1A). Additionally, the display 212 of the termination module 124a may be used to display field device activity information (e.g., measurement information, line voltage, etc.), data type information (e.g., analog signals, digital signals, etc.), field device status information (e.g., device on, device off, device error, etc.), and/or any other field device information. If the termination module 124a is configured to be communicatively coupled to multiple field devices (e.g., the field device 112a of FIG. 1A and other field devices (not shown)), the display 212 may be used to display the Field device information associated with all field devices of 124. In the example shown, display 212 is implemented using a liquid crystal display (LCD). However, in other exemplary embodiments, display 212 is implemented using any other suitable display technology.

To retrieve field device identification information and/or other field device information, a tagger 214 (eg, a termination tagger) is provided for each of the termination modules 124a-c. For example, when field device 112a is communicatively coupled to termination module 124a, tagger 214 of termination module 124a retrieves a field device identification from field device 112a (and/or other field devices communicatively coupled to termination module 124a) information and/or any other field device information, and display the information via the display 212 of the termination module 124a. The labeler 214 will be described in detail below in conjunction with FIG. 8 . Providing display 212 and labeler 214 reduces the cost and installation time associated with manually attaching labels to wires and/or buses associated with termination modules and field devices. However, in some exemplary embodiments, manual wire labeling may also be used in conjunction with display 212 and labeler 214 . For example, by using the display 212 and labeler 214 to determine which of the field devices 112a-c and 116a-c to connect to each of the termination modules 124a-c and 126a-c, the field Devices 112a-c and 116a-c are relatively rapidly communicatively coupled to I/O cards 132a-b and 134a-b. Subsequently, after installation is complete, tags may optionally be added to the buses or wires extending between the termination modules 124a-c and 126a-c and the field devices 112a-c and 116a-c. By configuring the display 212 and labeler 214 to display status information (e.g., device error, device warning, device on, device off, device disabled, etc.) associated cost and time.

To provide electrical power to the termination modules 124a - c, the I/O bus transceiver 206 and the display 212 , a power source 216 is provided to the marshalling cabinet 122 . In the example shown, the termination modules 124a-c use electrical power from the power supply 216 to power and/or Electrical power is provided for operation to the field devices. Additionally, in some examples, the marshalling cabinet 122 is provided with a power conditioner 218 for regulating or adjusting the power provided to each of the termination modules 124a-c along the outlet rails 202a-b. In some examples, the termination modules 124a-c may be powered from an external power source and/or a power conditioner via an integrated power injection bus communicatively coupled to the socket rails 202a-b.

FIG. 3 is another example marshalling cabinet 300 that may be used to implement the example marshalling cabinet 122 of FIG. 1A . In the depicted example, the marshalling cabinet 300 is provided with a wireless I/O bus communication controller 302 to communicate wirelessly with the controller 104 of FIG. 1A via a wireless universal I/O connection 304 . As shown in FIG. 3, a plurality of termination modules 306 substantially similar or identical to the termination modules 124a-c and 126a-c of FIG. Universal I/O bus 309 is communicatively coupled to wireless I/O bus communication controller 302 . In the example shown, wireless I/O bus communication controller 302 emulates an I/O card of controller 104 of FIG. 1A (e.g., I/O card 134a of FIG. device 104 for communication.

Unlike the example shown in FIG. 2 in which displays 212 are mounted on termination modules 124a-c, in the example shown in FIG. 300 in. In this manner, when one of the termination modules 306 is inserted into and communicatively coupled to a field device (e.g., one of the field devices 112a-c and 116a-c of FIG. A corresponding one of labeler 214 and display 310 of termination module 306 may be used to display field device identification information representing the field device connected to termination module 306 . Display 310 may also be used to display any other field device information. Marshalling cabinet 300 is provided with a power source 312 that is substantially similar or identical to power source 216 of FIG. 2 . Additionally, in some examples, marshalling cabinet 300 is provided with a power conditioner 314 that is substantially similar or identical to power conditioner 218 of FIG. 2 .

FIG. 4 shows a top view of the example termination module 124a of FIGS. 1A and 2 , and FIG. 5 shows a side view of the example termination module 124a of FIGS. 1A and 2 . In the illustrated example of FIG. 4 , the display 212 is on the top surface of the exemplary termination module 124a so that an operator or user can see during operation when the termination module 124a is inserted into the rail receptacle 202a ( FIG. 3 ). Display 212. As shown in the illustrated example of FIG. 5 , the exemplary termination module 124a is movably coupled to the base 402 . The exemplary termination module 124a includes a plurality of contacts 404 (two of which are shown) that communicatively and/or electrically couple the termination module 124a to the base 402 . In this manner, base 402 may be coupled to marshalling cabinet 122 ( FIGS. 1A and 2 ), and termination module 124a may be coupled to and removed from marshalling cabinet 122 via base 402 . Termination screws 406 (eg, field device interfaces) are provided for the base 402 to bolt or secure an electrically conductive communication medium (eg, a bus) to the field device 112a. When termination module 124a is movably coupled to bus 402, termination screw 406 is communicatively coupled to one or more of contacts 404 to enable communication of information between termination module 124a and field device 112a. In other exemplary embodiments, the base 402 may be provided with any other suitable type of field device interface (eg, a socket) in place of the terminal screws 406 . Additionally, although one field device interface (e.g., terminal screw 406) is shown, base 402 may be provided with additional field device interfaces configured to enable communicative coupling of multiple field devices to Termination module 124a.

To communicatively couple termination module 124a to universal I/O bus 208 of FIG. 2, base 402 is provided with universal I/O bus connector 408 (FIG. 5). Universal I/O bus connector 408 engages universal I/O bus 208 when a user inserts base 402 into socket rail 202a or socket rail 202b ( FIG. 2 ). Universal I/O bus connector 408 may be implemented using any suitable interface, including relatively simple interfaces such as isolated punch-through connectors. To enable communication of information between termination module 124a and I/O bus 208, I/O bus connector 408 is connected to one or more of contacts 404 of termination module 124a.

As shown in FIG. 5 , an optional display interface connector 410 may also be provided for the base 402 to communicatively couple the termination module 124a to an external display (eg, one of the displays 310 of FIG. 3 ). For example, if termination module 124a is implemented without display 212, termination module 124a may use display interface connector 410 to output field device identification information or any other field device information to an external display (e.g., the display of FIG. one of 310).

6 is a detailed block diagram of the exemplary termination module 124a of FIGS. 1A and 2, FIG. 7 is a detailed block diagram of the exemplary I/O card 132a of FIG. 1A, and FIG. A detailed block diagram of the sex tagger 214. The example termination module 124a, the example I/O card 132a, and the example tagger 214 may be implemented using any desired combination of hardware, firmware, and/or software. For example, one or more integrated circuits, discrete semiconductor components, or passive electronic components may be used. Additionally or alternatively, some or all of the example termination module 124a, the example I/O card 132a, and the example labeler 214, or portions thereof, may use instructions, code, and/or Implemented by other software and/or firmware, etc., when executed, for example, by a processor system (eg, the exemplary processor system 1610 of FIG. 16 ), the processes in FIGS. 10A, 10B, 11A, 11B, and 12 operation shown in the figure. Although the example termination module 124a, example I/O card 132a, and example labeler 214 are described as having one of the following blocks, the example termination module 124a, example I/O card 132a Each of the example labelers 214 provides two or more of any corresponding blocks described below.

Turning to FIG. 6, the example termination module 124a includes a general purpose I/O bus interface 602 to enable the example termination module 124a to communicate with the I/O cards 132a-b of FIG. 1A (or any other I/O card) . I/O bus interface 602 may be implemented, for example, using the RS-485 serial communication standard, Ethernet, or the like. To identify the address of the termination module 124a and/or the address of the I/O card 132a, an address identifier 604 is provided for the termination module 124a. Address identifier 604 may be configured to query I/O card 132a ( FIG. 1A ) for a termination module address (eg, a network address) when termination module 124a is inserted into marshalling cabinet 122 . In this manner, terminating module 124a can use the terminating module address as the source address when communicating information to I/O card 132a, and I/O card 132a uses the terminating module address when communicating information to terminating module 124a as the target address.

In order to control the various operations of the termination module 124a, an operation controller 606 is provided for the termination module 124a. In an exemplary embodiment, the operating controller may be implemented using a microprocessor or microcontroller. The operations controller 606 communicates instructions or commands to other portions of the example termination module 124a to control the operation of those portions.

An I/O bus communications processor 608 is provided for the exemplary termination module 124a to exchange information with the I/O card 132a via the general purpose I/O bus 136a. In the example shown, I/O bus communications processor 608 packages information for transmission to I/O card 132a and unpacks information received from I/O card 132a. In the example shown, I/O bus communications processor 608 generates header information for each packet to be transmitted, and reads header information from received packets. Exemplary header information includes destination address (e.g., network address of I/O card 132a), source address (e.g., network address of termination module 124a), packet type or data type (e.g., analog field device information, field device information , command information, temperature information, real-time data values, etc.), and error checking information (eg, cyclic redundancy check (CRC)). In some exemplary embodiments, I/O bus communication processor 608 and operations controller 606 may be implemented using the same microprocessor or microcontroller.

To provide (e.g., obtain and/or generate) field device identification information and/or any other field device information (e.g., activity information, data type information, status information, etc.), a tagger 214 (Fig. 2 and Figure 3). The labeler 214 will be described in detail below in conjunction with FIG. 8 . Termination module 124a also includes display 212 ( FIG. 2 ) for displaying field device identification information and/or any other field device information provided by labeler 214 .

In order to control the amount of power provided to field device 112a of FIG. 1A (or any other field device), a field power controller 610 is provided for termination module 124a. In the example shown, power supply 216 in marshalling cabinet 122 (FIG. 2) provides electrical power to termination module 124a to power the communication channel interface for communication with field device 112a. For example, some field devices communicate using 12 volts while other field devices communicate using 24 volts. In the example shown, the site power controller 610 is configured to regulate, adjust and step up and/or step down the electrical power provided by the power source 216 to the termination module 124a. In some examples, power conditioning is accomplished via a power conditioner 218 associated with the marshalling cabinet (FIG. 2). In some exemplary embodiments, the field power controller 610 is configured to limit the amount of electrical power used to communicate with and/or be delivered to field devices to substantially reduce or eliminate ignition in flammable or combustible environments. Risk of sparks.

To convert electrical power received from power supply 216 (FIG. 2) to electrical power for termination module 124a and/or field device 112a, power converter 612 is provided for termination module 124a. In the example shown, the circuitry used to implement termination module 124a uses one or more voltage levels (e.g., 3.3V) that are different than the voltage levels required by field device 112a. . Power converter 612 is configured to provide different voltage levels to termination module 124 a and field device 112 a using power received from power supply 216 . In the example shown, the electrical power output generated by power converter 612 is used to power termination module 124a and field device 112a, and to communicate information between termination module 124a and field device 112a. Some field device communication protocols require relatively higher or lower voltage levels and/or current levels than other communication protocols. In the example shown, field power controller 610 controls power converter 612 to provide voltage levels to power and communicate with field device 112a. But in other exemplary embodiments, the electrical power output generated by power converter 612 may be used to power termination module 124a while a separate power source external to marshalling cabinet 122 is used to power field device 112a.

To electrically isolate the circuitry of termination module 124a from I/O card 132a, one or more isolation devices 614 are provided for termination module 124a. Isolation device 614 may be implemented using galvanic isolators and/or opto-isolators. An exemplary isolation structure is described in detail below in conjunction with FIG. 9 .

To convert between analog and digital signals, the termination module 124a is provided with a digital-to-analog converter 616 and an analog-to-digital converter 618 . Digital-to-analog converter 616 is configured to convert the digitally represented analog value received from I/O card 132a into an analog value that may be communicated to field device 112a of FIG. 1A. Analog-to-digital converter 618 is configured to convert an analog value (eg, a measurement value) received from field device 112a into a digitally represented value that may be communicated to I/O card 132a. In an alternate exemplary embodiment in which termination module 124a is configured for digital communication with field device 112a, digital-to-analog converter 616 and analog-to-digital converter 618 may be omitted from termination module 124a.

To control the communication with the field device 112a, a field device communication processor 620 is provided for the termination module 124a. Field device communication processor 620 ensures that information received from I/O card 132a is in the correct format and voltage type (eg, analog or digital) to be transmitted to field device 112a. If the field device 112a is configured to communicate using digital information, the field device communication processor 620 is also configured to package or unpack the information. In addition, field device communication processor 620 is configured to extract information received from field device 112a and communicate the information to analog-to-digital converter 618 and/or I/O bus communication processor 608 for subsequent communication to the I/O bus communication processor 608. O card 132a. In some examples, field device communication processor 620 assists in identifying an appropriate communication protocol associated with field device 112a. For example, termination module 124a may be configured to communicate with Fieldbus compliant devices, including Profibus PA devices or FF-H1 devices. In such an example, the field device communication processor 620 implements an auto-sensing routine in which the field device communication processor 620 formats a test signal or request corresponding to the Profibus PA communication protocol. If field device 112a responds to the request, field device 112a is identified as a Profibus PA compliant device and all future communications are formatted based on the Profibus PA protocol. If the field device 112a does not respond to the Profibus PA formatted request, the field device communication processor 620 formats a second request corresponding to the FF-H1 communication protocol, based on whether the field device 112a responds to the second request to confirm whether the field device 112a is a FF-H1 compliant device. If the termination module 124a is configured to communicate using another protocol (eg, HART), the field device communication processor 620 may generate additional requests until an appropriate communication protocol for the field device 112a is detected.

In some examples, such auto-sensing routines are implemented on a periodic (non-periodic) basis (e.g., after a certain threshold period of time) to detect any changes. For example, an auto-sensing routine may detect a first active or primary field device (eg, field device 112a ) and a second backup field device (not shown) on wire 130a communicatively coupled to termination module 124a. If the first field device fails, the termination module 124a can detect this by loss of communication with the first field device. In some such examples, the auto-sensing routine detects the spare device and compares device information (eg, placeholder information, device type, vendor, revision, etc.) to that of the failed device. In some examples, if the device information matches (e.g., the primary field device and the backup device are the same device except for the serial number), the termination module 124a automatically swaps the primary field device for the backup field device to continue monitoring the process system. control. Additionally or alternatively, in some examples, if the device information contains some differences (e.g., different versions or vendors), the termination module 124a is automatically enabled and begins communicating with the alternate field device, but retains the "alternate" name (while continue to denote the first field device as the primary field device, even though the first field device is disconnected), until the operator or engineer specifies removal of the first field device and/or designates the backup field device as the new in-service or Major equipment.

In the example shown, the field device communication processor 620 is also configured to time stamp information received from the field device 112a. Generating timestamps at the termination module 124a facilitates implementing sequence-of-event (SOE) operations using sub-microsecond timestamp precision. For example, the time stamp and corresponding information may be communicated to controller 104 and/or workstation 102 . A sequence of events, such as performed by workstation 102 (FIG. 1A) (or any other processor system), can then be used to analyze what happened before, during, and/or after a particular operating state (e.g., a failure mode) to determine What causes a particular operational state to occur. Sub-microsecond timestamps enable events to be captured with a relatively high granularity. In some exemplary implementations, the field device communications processor and operations controller 606 may be implemented using the same microprocessor or microcontroller.

Typically, field device communication controllers like field device communication controller 620 are provided with communication protocol functions or other communication functions (e.g., Fieldbus communication protocol functions, HART communication protocol functions, etc.) A device communication controller is configured to communicate with field devices. For example, if the field device 112a is implemented as a HART device, the field device communication controller 620 of the termination module 124a is provided with HART communication protocol functionality. When termination module 124a receives information from I/O card 132a intended for field device 112a, field device communication controller 620 formats the information according to the HART communication protocol and communicates the information to field device 112a.

In the example shown, field device communication controller 620 is configured to process pass-through messages. Passing messages originate at a workstation (e.g., workstation 102 of FIG. 1A ) and pass as payload (e.g., the data portion of a communication packet) through a controller (e.g., controller 104 of FIG. 1A ) and on to a terminating module (e.g., , the termination module 124a) of FIG. 1A) for delivery to a field device (eg, field device 112a). For example, messages originating at workstation 102 intended for delivery to field device 112a are tagged at workstation 102 with a communication protocol descriptor (eg, a HART protocol descriptor) and/or formatted according to the communication protocol of field device 112a. The workstation 102 then wraps the message into the payload of one or more communication packets to pass the message as a pass-through message from the workstation 102 through the I/O controller 104 to the termination module 124a. Packetized messages include messages within packetized header information, eg, according to a communication protocol used to communicate with field devices (eg, Fieldbus protocol, HART protocol, etc.). When termination module 124a receives a communication packet from I/O card 132 that contains a message passing through, I/O bus communication processor 608 (FIG. 6) extracts the payload from the received communication packet. The field device communication controller 620 (FIG. 6) then unpacks the passing message from the payload, formats the message according to the communication protocol descriptor generated by the workstation 102 (if not already formatted at the workstation 102), and converts the message to to field device 112a.

Field device communication controller 620 is also configured to communicate passing messages to workstation 102 in a similar manner. For example, if field device 112a generates a message intended for delivery to workstation 102 (e.g., in response to a workstation message or any other message), field device communication controller 620 encapsulates the message from field device 112a into one or more communication packets and I/O bus communications processor 608 transmits one or more packets containing the packetized message to I/O card 1332a. When workstation 102 receives a packet containing a wrapped message from controller 104, workstation 102 may unpack and process the message.

Termination module 124a is provided with a field device interface 622 configured to communicatively couple termination module 124a to a field device (eg, field device 112a of FIG. 1A ). For example, field device interface 622 may be communicatively coupled to terminal screw 406 of FIGS. 4 and 5 via one or more of contacts 404 ( FIG. 4 ).

In some examples, the termination module 124a is provided with a fieldbus diagnostic analyzer 624 configured to provide advanced diagnostics related to the associated field device when the field device is fieldbus compliant. Fieldbus diagnostic analyzer 624 performs measurements related to the condition of the physical wiring (eg, first conductor 130a of FIG. 1A ) and associated communications during operation. For example, fieldbus diagnostic analyzer 624 may measure supply voltage, load current, signal level, line noise, and/or bounce. Although advanced diagnostic modules with similar functionality could be incorporated into conventional fieldbus architectures, the diagnostics provided by fieldbus diagnostic analyzer 624 are more reliable and/or robust because termination module 124a is only coupled in a point-to-point architecture to a single field devices instead of having to diagnose multiple devices in the multidrop architecture of traditional fieldbus segments.

Turning now to FIG. 7, the example I/O card 132a of FIG. 1A includes a communication interface 702 that communicatively couples the I/O card 132a to the controller 104 (FIG. 1A). Additionally, the example I/O card 132a includes a communications processor 704 to control communications with the controller 104 and to package and unpack information exchanged with the controller 104 . In the example shown, communication interface 702 and communication processor 704 are configured to communicate information intended for controller 104 and information intended for workstation 102 ( FIG. 1A ) to controller 104 . To communicate information intended for workstation 102, communication interface 702 may be configured to communicate information (e.g., from field devices 112a-c) according to a communication protocol (e.g., Transmission Control Protocol (TCP), User Datagram Protocol (UDP), etc.) , termination modules 124a-c, and/or I/O card 132a information) into the payload of one or more communication packets, and transmit the packet containing the information to workstation 102. Workstation 102 may then unpack the payload from the received packet and unpack the information in the payload. In the example shown, the information in the payload of the packet communicated by communication interface 702 to workstation 102 may contain one or more packetizers. For example, information originating from a field device (e.g., field device 112a) may be encapsulated in a field device communication protocol wrapper (e.g., FOUNDATION Fieldbus communication protocol wrapper, HART communication protocol wrapper, etc.), which is the communication interface 702 based on A TCP-based protocol, a UDP-based protocol, or any other protocol packetized to enable the controller 104 to subsequently communicate the information to the workstation 102 . In a similar manner, communication interface 702 is configured to unwrap information communicated by workstation 102 to controller 104 and intended for communication to field devices 112a-c, termination modules 124a-c, and/or I/O card 132a.

In an alternative exemplary embodiment, the communication interface 702 and the communication processor 704 may communicate information (with or without the aid of a field device communication protocol wrapper) to the controller 104, and the controller 104 may communicate information intended to be communicated to the workstation 102. Information is packaged in the same manner as above. Communication interface 702 and communication processor 704 may be implemented using any wired or wireless communication standard.

In alternative exemplary implementations, such as the example shown in FIG. 1C , communication interface 702 and communication processor 704 may be configured to communicate with workstation 102 and/or controller 162 via LAN 106 .

To enable a user to interact with and/or access I/O card 132a, one or more user interface ports 706 are provided for I/O card 132a. In the example shown, user interface ports 706 include a keyboard interface port 703 and a portable handheld computer (eg, personal digital assistant (PDA), tablet PC, etc.) interface port 707 . For example, a PDA 708 is shown communicatively coupled to the user interface port 706 using wireless communications.

To communicatively couple I/O card 132a to general purpose I/O bus 136a (FIG. 1A), I/O bus interface 710 is provided for I/O card 132a. To process communication information exchanged via I/O bus 136a and to control communications via I/O bus 136a, I/O card 132a is provided with an I/O bus communication processor 712 . I/O bus interface 710 may be similar or identical to I/O bus interface 602 of FIG. 6 , and I/O bus communication processor 712 may be similar or identical to I/O bus communication processor 608 of FIG. 6 . To convert the electrical power provided by the controller 104 of FIG. 1A to the electrical power required to power and operate the I/O card 132a and/or communicate with the termination modules 124a-c, a power converter 714 is provided for the I/O card 132a. .

Turning now to FIG. 8 , the exemplary labeler 214 includes a communication interface 802 configured to communicatively couple the labeler 214 to a termination module (e.g., of FIGS. 1A , 2 , 4 , 5 , and 6 ). Termination module 124a) and/or a field device (e.g., field device 112a of FIG. 1A) to retrieve field device identification information (e.g., device tag value, device name, electronic serial number, etc.) and/or other field device information (eg, activity information, data type information, status information, etc.). To control communications with the termination module 124a and/or the field device 112a, a communications processor 804 is provided for the tagger 214 .

To detect the connection of a field device (eg, field device 112a of FIG. 1A ), the tagger 214 is provided with a connection detector 806 . Connection detector 806 may be implemented using, for example, a voltage sensor, current sensor, logic circuit, etc. that senses when field device 112a is connected to termination module 124a. In the example shown, when connection detector 806 determines that field device 112a has been connected to termination module 124a, connection detector 806 causes a notification (e.g., an interrupt) to communicate processor 804 indicating the detected connection . The communications processor 804 then queries the termination module 124a and/or the field device 112a for the field device identification information of the field device 112a. In an exemplary embodiment, connection detector 806 may also be configured to determine the type of connection communicatively coupling field device 112a to termination module 124a, for example, a multidrop connection, a point-to-point connection, a field device in service and a non-operating field device. Point-to-point connections, wireless mesh network connections, optical connections, etc. for operational standby field devices.

A display interface 808 is provided for the labeler 214 for displaying field device identification information and/or other field device information. In the example shown, display interface 808 is configured to drive and control a liquid crystal display (LCD). For example, display interface 808 may be configured to control LCD display 212 (FIG. 2) mounted on termination module 124a or LCD display 310 mounted on marshalling cabinet 300 (FIG. 3). In other exemplary embodiments, however, display interface 808 may alternatively be configured to drive other display types.

To detect activity of the field device 112a, the tagger 214 is provided with a field device activity detector 810 . In the example shown, when communications processor 804 receives data from termination module 124 a and/or field device 112 a , communications processor 804 communicates the received data to field device activity detector 810 . Field device activity detector 810 then extracts process variable (PV) values from the data, including, for example, measurement information generated by field device 112a (e.g., temperature, pressure, line voltage, etc.), or other monitoring information (e.g., valve closure, valve open, etc.). Display interface 808 may then display field device activity information (eg, PV values, measurement information, monitoring information, etc.).

To detect the condition of the field device 112a, the tagger 214 is provided with a field device condition detector 812. Field device status detector 812 is configured to extract status information associated with field device 112a (e.g., device on, device off, Device error, device warning, device health (open loop, short circuit, etc.), device communication status, etc.). In some examples, the status information includes information based on data obtained via fieldbus diagnostic analyzer 624 (FIG. 6). Display interface 808 may then display the received status information.

To identify field device 112a, tagger 214 is provided with field device identifier 814 . Field device identifier 814 is configured to extract field device identification information (eg, device tag value, device name, electronic serial number, etc.) from data received by communications processor 804 from termination module 124a and/or field device 112a. The display interface 808 may then display the field device identification information. In an exemplary embodiment, field device identifier 814 may also be configured to detect a field device type (eg, valve actuator, pressure sensor, temperature sensor, flow sensor, etc.). In some examples, the field device identifier 814 is configured to identify an appropriate communication protocol associated with the field device 112a in the same or similar manner as or in combination with the field device communication processor 620 described above in connection with FIG. 6 .

Data type identifier 816 is provided to tagger 214 in order to identify the type of data (eg, analog or digital) associated with field device 112a. The data type identifier 816 is configured to extract data type identification information from data received by the communications processor from the termination module 124a and/or the field device 112a. For example, termination module 124a may store a data type descriptor variable indicating the type (e.g., analog, digital, etc.) with which the field device is configured to communicate, and termination module 124a may communicate the data type descriptor variable to the tagger 214 communications processor 804 . Display interface 808 may then display the data type. In some examples, data type identifier 816 uses the communication protocol identified by field device identifier 814 to determine the data type associated with field device 112a.

9 illustrates an isolation circuit configuration that may be implemented in conjunction with the exemplary termination modules 124a and 124b of FIG. 1A to electrically isolate the termination modules 124a-b from each other and to electrically isolate the field devices 112a-b from the general purpose /O bus 136a is electrically isolated. In the example shown, each of the termination modules 124a-b includes respective termination module circuits 902 and 904 (eg, one or more of the blocks described above in connection with FIG. 6). Additionally, the termination modules 124a-b are connected to their respective field devices 112a-b via the field junction box 120a. Additionally, termination modules 124a - b are connected to general purpose I/O bus 136a and power supply 216 . To electrically isolate the termination module circuit 902 from the general purpose I/O bus 136a, an isolation circuit 906 is provided for the termination module 124a. In this manner, the termination module circuit 902 can be configured so that if power surges and other power changes occur in the field device 112a, without affecting the voltage of the universal I/O bus 136a and causing damage to the I/O card In the event of damage to field device 132a (FIG. 1A), it follows (eg, floats) the voltage level of field device 112a. Termination module 124b also includes isolation circuitry 908 configured to isolate termination module circuitry 904 from general purpose I/O bus 136a. The isolation circuits 906 and 908 and any other isolation circuits implemented in the termination modules 124a-b may be implemented using optical isolation circuits and electrical isolation circuits.

To isolate the termination module circuit 902 from the power source 216, an isolation circuit 910 is provided for the termination module 124a. Similarly, an isolation circuit 912 is provided for the termination module 124b to isolate the termination module circuit 904 from the power supply 216 . By isolating the termination module circuits 902 and 904 from the power supply 216 , any power variations (eg, power surges, current spikes, etc.) associated with the field devices 112a - b cannot damage the power supply 216 . Furthermore, any power variation in one of the termination modules 124a-b will not damage or affect the operation of the other of the termination modules 124a-b.

In known process control systems, the isolation circuits are provided in known marshalling cabinets, thereby reducing the amount of space available for known termination modules. But providing isolation circuits 906, 908, 910, and 912 in termination modules 124a and 124b as shown in the example shown in FIG. The amount of space required thus increases the amount of space available for termination modules (eg, termination modules 124a-c and 126a-c). In addition, implementing isolation circuits (e.g., isolation circuits 906, 908, 910, and 912) in termination modules (e.g., termination modules 124a-b) enables selective use of isolation circuits with only termination modules that require isolation . For example, some of the termination modules 124a-c and 126a-c of FIG. 1A may be implemented without isolation circuitry.

10A, 10B, 11A, 11B, 12, and 15 are flowcharts of exemplary methods that may be used to implement a termination module (e.g., the termination modules of FIGS. 1A, 2, and 4-6) 124a, and/or the termination module 1332a of Figure 13B), I/O card (for example, the I/O card 132a of Figure 1A and Figure 7), and labeler (for example, the label of Figure 2, Figure 3 and Figure 8 device 214). In some example embodiments, the example methods of FIGS. 10A, 10B, 11A, 11B, 12, and 15 are implemented using machine-readable instructions, including instructions for use by a processor (eg, A program executed by a processor 1612) shown in the exemplary processor system 1610 of FIG. The programs may be embodied as software stored on tangible media such as CD-ROMs, floppy disks, hard drives, digital versatile disks (DVDs), and memory associated with processor 1612, and/or in known ways as firmware and/or dedicated hardware. Furthermore, although the exemplary procedures are described with reference to the flowcharts shown in FIGS. Many other methods of the example termination module 124a, the example termination module 1332a, the example I/O card 132a, and the example labeler 214. For example, the order of execution of the blocks may be changed, and/or some of the blocks may be changed, removed, or combined.

Turning specifically to FIGS. 10A and 10B , the example method of FIGS. 10A and 10B is described in conjunction with the example termination module 124a of FIGS. 1A , 2 , and 4-6 . However, the exemplary methods of FIGS. 10A and 10B can be used to implement any other termination module. The flowcharts of FIGS. 10A and 10B are used to describe how the exemplary termination module 124a communicates information between the field device 112a and the I/O card 132a. Initially, the termination module 124a determines whether it has received communication information (block 1002). For example, termination module 124a determines that it has received a communication if I/O bus communication processor 608 (FIG. 6) or field device communication processor 620 indicates, eg, via an interrupt or a status register, that a communication has been received. If the terminating module 124a determines that it has not received the communication (block 1002), control remains at block 1002 until the terminating module 124a receives the communication.

If the termination module 124a receives a communication (block 1002), the termination module 124a determines whether it is receiving a communication from a field device (e.g., the field device of FIG. 112a) Communication information is received (block 1004). If the termination module 124a determines that it has received communications from the field device 112a (block 1004), the field device communications processor 620 extracts field device information from the received communications associated with the field device 112a based on the field device communications protocol and field device identification information (block 1006). Field device information may include, for example, field device identification information (e.g., device tag, electronic serial number, etc.), field device status information (e.g., communication status, diagnostic health information (open loop, short circuit, etc.)), field device activity information (e.g., , process variable (PV) value), field device description information (for example, field device type or function, for example, valve actuator, temperature sensor, pressure sensor, flow sensor, etc.), field device connection configuration information (for example, multipoint branch bus connection, point-to-point connection, etc.), field device bus or segment identification information (e.g., field device bus or field device segment via which the field device is communicatively coupled to the terminating module), and/or field device Data type information (e.g., analog input (AI) data type, analog output (AO) data type, discrete input (DI) data type (e.g., digital input data type), discrete output (DO) data type (e.g., digital output data type), etc.). The field device communication protocol may be any protocol used by the field device 112a (e.g., Fieldbus protocol (e.g., FF-H1), HART protocol, AS-I protocol, Profibus protocol (e.g., Profibus PA), etc. In alternative examples In an exemplary embodiment, at block 1006, the field device communication processor 620 extracts only the field device information from the received communication information and stores the field device identification information identifying the field device 112a in the termination module 124a. For example, in the When field device 112a is initially connected to termination module 124a, field device 112a may transmit its identification information to termination module 124a, and termination module 124a may store the identification information.

The field device communication processor 620 then determines whether an analog-to-digital conversion is required (block 1008). For example, if the field device 112a communicates an analog measurement, the field device communication processor 620 determines that an analog-to-digital conversion is required or required (block 1008). If analog-to-digital conversion is required, analog-to-digital converter 618 (FIG. 6) performs conversion on the received information (block 1010).

After analog-to-digital conversion (block 1010) or if no analog-to-digital conversion is required (block 1008), the field device communication processor 620 identifies the data type (e.g., analog, digital, temperature measurement, etc.) associated with the received field device information ) (block 1012), and generate a data type descriptor corresponding to the received field device information (block 1014). For example, termination module 124a may store a data type descriptor that indicates the type of data that is always received from field device 112a, or field device 112a may transmit the data type to termination module 124a, and field device communication processor 620 uses its At block 1010 a data type descriptor is generated.

I/O bus communications processor 608 (FIG. 6) determines the destination address of I/O card 132a (block 1016) to which termination module 124a is to communicate information received from field device 112a. For example, communications processor 608 (FIG. 6) may obtain the target address of I/O card 132a from address identifier 604 (FIG. 6). Additionally, the I/O bus communications processor 608 determines or generates error checking data (block 1020) for transmission to the I/O card 132a to ensure that field device information received by the I/O card 132a is correct. For example, I/O bus communications processor 608 may generate cyclic redundancy check (CRC) error checking bits.

The I/O bus communication processor 608 then packages the field device information, field device identification information, data type descriptor, destination address of the I/O card 132a, source address of the termination module 124a, and error correction based on the I/O bus communication protocol. test data (block 1022). The I/O bus communication protocol may be implemented using, for example, a TCP-based protocol, a UDP-based protocol, or the like. I/O bus communication processor 608 may obtain the source address of termination module 124a from address identifier 604 (FIG. 6). I/O bus interface 602 (FIG. 6) then combines packetized information generated and transmitted by other termination modules (e.g., termination modules 124b and 124c of FIG. 1A) via general purpose I/O bus 136a (FIGS. 1A and 2). Packetized information is transmitted (block 1024). For example, I/O bus interface 602 may be provided with an arbitration circuit or device that sniffs or monitors general purpose I/O bus 136a to determine when general purpose I/O bus 136a is available (e.g., not in use by termination modules 124b-c). ) to transfer information from the termination module 124a to the I/O card 132a.

If the termination module 124b determines at block 1004 that the communication detected at block 1002 is not from the field device 112a (e.g., the communication is from the I/O card 132a), the I/O bus communication processor 608 (FIG. The communication information extracts the destination address of the communication information (block 1026). The I/O bus communications processor 608 then determines whether the extracted target address matches the target address of the termination module 124a obtained from the address identifier 604 (block 1028). If the destination address does not match the address of the termination module 124a (eg, the received information was not intended for delivery to the termination module 124a) (block 1028), control returns to block 1002 (FIG. 10A). Otherwise, if the destination address matches the address of the termination module 124a (e.g., the received message was not intended for delivery to the termination module 124a) (block 1028), the I/O bus communications processor 608 communicates over the I/O bus The communication protocol extracts field device information from the received communication (block 1030), and verifies the integrity of the data using, for example, a CRC verification process based on error detection information in the received communication (block 1032). Although not shown, if the I/O bus communications processor 608 determines at block 1032 that there is an error in the received communications, the I/O bus communications processor 608 sends a message requesting retransmission to the I/O card 132a.

After data integrity is verified (block 1032), the I/O bus communication processor 608 (or field device communication processor 620) determines whether digital-to-analog conversion is required (block 1034). For example, if the data type descriptor stored in termination module 124a indicates that field device 112a requires analog information, then I/O bus communications processor 608 determines that digital-to-analog conversion is required (block 1034). If digital-to-analog conversion is required (block 1034), the digital-to-analog converter 616 (FIG. 6) performs digital-to-analog conversion on the field device information (block 1036). After performing the digital-to-analog conversion (block 1036) or if no digital-to-analog conversion is required (block 1034), the field device communication processor 620 communicates the field device communication processor 620 via the field device interface 622 (FIG. The device information is communicated to field device 112a.

After the field device communication processor 620 has communicated the field device information to the field device 112a, or after the I/O bus communication processor 608 has communicated the field device information to the I/O card 132a, the process of FIGS. 10A and 10B ends and/or or return control to, for example, a calling procedure or function.

11A and 11B illustrate flow diagrams of exemplary methods that may be used to implement the I/O card 132a of FIG. 1A to exchange information between the termination module 124a of FIG. 1A and the controller 104 . Initially, the I/O card 132a determines whether it has received a communication (block 1102). For example, I/O card 132a determines that it received communications if communications processor 704 (FIG. 7) indicates, eg, via an interrupt or a status register, that it received communications. If the I/O card 132a determines that it has not received the communication (block 1102), control remains at block 1102 until the I/O card 132a receives the communication.

If the I/O card 132a receives a communication (block 1102), the I/O card 132a determines whether it has received a communication from the controller 104 (FIG. ). If the I/O card 132a determines that it has received communications from the controller 104 (block 1104), the communications processor 704 extracts the termination module information (which may include field device information).

The communications processor 704 identifies the type of data associated with the received termination module information (e.g., field device analog information, field device digital information, termination module control information to control or configure the termination module, etc.), and generates A data type descriptor corresponding to the received termination module information (block 1110). In an alternative exemplary embodiment, the data type descriptor is generated at the workstation 102 (FIG. 1A), and the communications processor 704 need not generate the data type descriptor.

I/O bus communications processor 712 (FIG. 7) then determines the target address for termination module 124a (block 1112). In addition, the I/O bus communication processor 712 determines error checking data (block 1114) to transmit along with the terminating module information to the terminating module 124a to ensure that the terminating module 124a receives the information without error. For example, I/O bus communication processor 712 may generate cyclic redundancy check (CRC) error checking bits.

The I/O bus communication processor 712 then packs the termination module information, the data type descriptor, the destination address of the termination module 124a, the source address of the termination module 124a, and error checking data based on the I/O bus communication protocol (block 1116 ). I/O bus interface 710 (FIG. 7) then transfers the packet via general purpose I/O bus 136a (FIGS. 1A and 2) in conjunction with packetized information destined for other termination modules (e.g., termination modules 124b and 124c of FIG. 1A). information (block 1118). For example, the I/O bus communications processor 712 may use, for example, the target addresses of the termination modules 124b and 124c to package other termination module information and provide a link for all termination modules 124a via the common I/O bus 136a using the RS-485 standard. -c transmits termination module information. Each of the termination modules 124a-c may fetch its corresponding information from the general purpose I/O bus 136a based on the target address provided by the I/O card 132a.

If the I/O card 132a determines at block 1104 that the communication detected at block 1102 is not from the controller 104 (e.g., the communication is from one of the termination modules 124a-c), the I/O bus communication processor 712 (FIG. 7) extracts the source address (eg, the source address of one of the terminating modules 124a-c) from the received communication (block 1122). The I/O bus communication processor 712 then extracts the data type descriptor (eg, digitally encoded analog data type, digital data type, temperature data type, etc.) (block 1124). The I/O bus communication processor 712 also extracts termination module information (which may include field device information) from the received communication based on the I/O bus communication protocol (block 1126), and based on the error detection information in the received communication The integrity of the data is verified using, for example, a CRC verification process (block 1128). Although not shown, if the I/O bus communication processor 712 determines at block 1128 that there is an error in the received communication information, the I/O bus communication processor 712 sends a retransmission request message to the The source address associated with the terminating module.

After verifying the integrity of the data (block 1128), the communication processor 704 packages the termination module information (using the source address and data type descriptor of the termination module), and the communication interface 702 transmits the packaged information to the controller 104 (block 1128). 1130). If information is intended to be communicated to workstation 102 , controller 104 may subsequently communicate the information to workstation 102 . After the communication interface 702 transmits information to the controller 104 or the I/O bus interface 710 transmits the termination module information to the termination module 124a, the process of FIGS. 11A and 11B ends and/or control returns to, for example, the calling process or Function.

12 is a flowchart of an exemplary method that may be used to implement the labeler 214 of FIGS. Information associated with a field device (eg, field device 112a of FIG. 1A ) of termination module 124a) of FIGS. 4-6. Initially, connection detector 806 (FIG. 8) determines whether a field device (e.g., field device 112a) is connected to termination module 124a (e.g., connected to termination screw 406 of FIGS. interface 622) (block 1202). If connection detector 806 determines that field device 112a (or any other field device) is not connected to termination module 124a (block 1202), control remains at frame 1202 until connection detector 806 determines that field device 112a (or any other field device) ) is connected to the termination module 124a.

If connection detector 806 determines that field device 112a is connected to termination module 124a (block 1202), field device identifier 814 obtains field device identification information (e.g., device tag value, device name, electronic serial number, etc.) Device 112a (block 1204). For example, field device identifier 814 may send a query to field device 112a requesting that field device 112a transmit its field device identification information. In another exemplary embodiment, field device 112a may automatically transfer its field device identification information to field device identifier 814 upon initial connection to termination module 124a.

The field device identifier 814 then determines whether to assign the field device 112a to communicate with the I/O card 132a via the universal I/O bus 136a based on the field device identification information (block 1206). For example, field device identifier 814 may communicate field device identification information to I/O card 132a via termination module 124a, and I/O card 132a may match the field device identification information stored in data structure 133 (FIG. 1A) or workstation The field device identification numbers in similar data structures stored in 102 are compared. Data structure 133 may be populated by an engineer, operator, or user with field device identification numbers of field devices (eg, field devices 112a-c) to communicate with I/O card 132a via general purpose I/O bus 136a. If I/O card 132a determines to assign field device 112a to I/O bus 136a and/or I/O card 132a, I/O card 132a transmits an acknowledgment message to field device identifier 814.

If the field device identifier 814 determines that the field device 112a is not assigned to communicate via the I/O bus 136a (block 1206), the display interface 808 (FIG. 8) displays an error message (block 1208). Otherwise, the display interface 808 displays the field device identification information (block 1210). In the example shown, field device status detector 812 detects a field device status (eg, device on, device off, device error, etc.), and display interface 808 displays the status information (block 1212 ). Additionally, field device activity detector 810 (FIG. 8) detects activity (eg, measurement and/or monitoring information) of field device 112a, and display interface 808 displays the activity information (block 1214). Additionally, data type detector 816 (FIG. 8) detects the data type (eg, analog, digital, etc.) of field device 112a, and display interface 808 displays the data type (block 1216).

After the display interface 808 displays an error message (block 1208) or after the display interface 808 displays a data type (block 1216), the labeler 214 based on, for example, whether the termination module 124a is closed or unplugged from the marshalling cabinet 122 (FIGS. 1A and 2) Determine if it should continue monitoring (block 1218). If the tagger 214 determines that it should continue monitoring, control returns to block 1202 . Otherwise, the example process of FIG. 12 ends and/or control returns to the calling function or process.

13A-B are diagrams illustrating another example process control system 1300 before and after implementing the teachings disclosed herein relative to an example Profibus PA process area 1302 and an example FOUNDATION Fieldbus H1 (FF-H1) process area 1304 block diagram. Although process control systems including Profibus PA and FOUNDATION fieldbus process areas are uncommon, both are shown in the example shown for the sake of explanation. Furthermore, for the sake of explanation, the example process control system 1300 of FIGS. 13A-B is described using the same reference numerals used for common parts described in connection with the example process control system 100 of FIG. 1A . Thus, in the illustrated example of FIG. 13A , process control system 1300 includes workstation 102 communicatively coupled to controller 1306 via LAN 106 . The example controller 1306 may be substantially similar or identical to any of the controllers 104, 152, 162 of FIGS. 1A-C. Additionally, the example process control system 1300 includes a first process area 114 associated with field devices 112a - c that are communicatively coupled to termination modules 124a - c within an example marshalling cabinet 1308 . The exemplary marshalling cabinet may be substantially similar or identical to any of the marshalling cabinets 122, 300 of FIGS. 1A, 2, and 3. Termination modules 124a-c are communicatively coupled to I/O cards 132a-b within controller 1306 via a first general purpose I/O bus 136a. Additionally, in the example shown, marshalling cabinet 1308 includes receptacle rails 1310 for receiving additional termination modules that are substantially identical to receptacle rails 202a-b, 308a-b described above in connection with FIGS. 2 and 3 . similar or identical.

In the illustrated example of FIG. 13A , the exemplary process control system 100 includes field devices 1312a-c in a Profibus PA process area 1302 and 1314a-c in a FF-H1 process control area 1304 implemented using conventional fieldbus architectures and components. (Both Profibus PA and FF-H1 are protocols associated with the fieldbus protocol family). Thus, field devices 1312a-c and 1314a-c are communicatively coupled to controller 1306 via respective trunks or segments 1316a-b. Typically, a Fieldbus trunk or segment is a single cable, comprising twisted pairs of wires, that carries digital signals and DC power to connect multiple field devices to a distributed control system (DCS) or other control system host. Due to a number of constraints, fieldbus segments are typically limited to a maximum length of 1900 meters and can connect up to 16 different field devices. As shown in the illustrated example, segments 1316a - b are communicatively coupled to respective I/O cards 1318a - b and 1320a - b within controller 1306 . In the example shown, each of the segments 1316a-b is coupled to two I/O cards 1318a-b or 1320a-b to provide redundancy. In some examples, the I/O cards 1318a-b and/or 1320a-b may be located separately from each other and/or from the I/O cards 132a-b associated with the field devices 112a-c of the first process area 114. in different controllers.

In the illustrated example of FIG. 13A , segment 1316a corresponding to exemplary Profibus PA process area 1302 is coupled to I/O cards 1318a - b via DP/PA segment couplers 1322 . Similarly, segment 1316b corresponding to exemplary FF-H1 process area 1304 is coupled to I/O cards 1320a - b via power supply 1324 . In some examples, DP/PA segment couplers 1322 and power supplies 1324 provide power conditioning functions on respective segments 1316a-b. Additionally, in the example shown, DP/PA segment couplers 1322 and power supplies 1324 are coupled to respective advanced diagnostic modules 1325a-b, which can monitor the physical layer of the corresponding segment 1316a-b during operation as well as the 1316a-b communication.

In the example shown, field devices 1312a-c and 1314a-c are coupled to respective segments 1316a-b via respective cable spurs (spurs) 1326a-c and 1328a-c. In a fieldbus architecture, each cable junction connects the corresponding field device to the segment in parallel. Thus, in many process control systems as shown in the illustrated example, each cable junction point 1326a-c and 1328a-c is routed via a section protector 1330a-b (sometimes called a device coupler or field shield) Coupled to the corresponding segment 1316a-b to provide short circuit protection against a short circuit in any one of the field devices 1312a-c and 1314a-c that shorts the entire segment. In some examples, segment protectors 1330a-b limit the current flow (eg, to 40mA) on each of cable junction points 1326a-c and 1328a-c. In some examples, a segment protector 1330a-b is also used to properly terminate each segment 1316a-b at the end near the field device, while a DP/PA segment coupler 1322 and power supply 1324 are used at the end near the controller Terminating segments 1316a-b. Without proper termination at both ends of the segments 1316a-b, communication errors can occur due to signal reflections.

Although, as described above, fieldbus architectures offer many advantages, they also pose challenges in terms of implementation complexity and cost. For example, the complexity of fieldbus systems forces engineers to carefully design each segment, taking into account, among other factors, the number of devices served by each segment, the length of cables required, and the power requirements involved, while ensuring that each segment is properly Ground is terminated and protected against shorts, opens, and/or other segment faults. In addition to the time and cost of initially configuring such a fieldbus architecture, there are many components associated with such an implementation, including DP/PA segment couplers 1322 or power supplies 1324, segment protectors 1330a-b, length of segment cables ( Additional costs associated with multiple cables for redundancy), and I/O cards 1318a-b and 1320a-b) are included in some instances. However, with the implementation of the teachings disclosed herein, the design complexity and costs involved in the implementation and maintenance of fieldbus systems are significantly reduced.

FIG. 13B is a block diagram illustrating the example process control system 1300 of FIG. 13A after implementing the teachings disclosed herein. As shown in the illustrated example, the cable relay points 1326a-c and 1328a-c of the field devices 1312a-c and 1314a-c are communicatively coupled directly to corresponding termination modules 1332a-f, which have been plugged into those shown in FIG. into sockets on socket rails 1310 of marshalling cabinet 1308 as shown. That is, contrary to the typical arrangement of field devices in a multidrop architecture, in the example shown, each Fieldbus compliant field device 1312a-c and 1314a-c is in point-to-point communication with a corresponding termination module 1332a-f middle. Termination modules 1332a-f may be substantially similar or identical to termination modules 124a-c and 126a-c described above, implemented in field devices 1312a-c and 1314a-c via general purpose I/O bus 136a in the same manner as described above. Communication with I/O cards 132a-b. In this manner, separate I/O cards 1318a-b and 1320a-b (FIG. 13A ), and any type of field device and associated I/O can be combined into a single marshalling cabinet 1308. Similarly, the need for cable trunks or segments 1316a-b (FIG. 13A) along with any associated isolation is eliminated. Also, in some examples, the universal I/O bus 136a provides a high-speed communication backbone for much faster communication (e.g., via optic fibre cable). Still further, in some examples, the universal I/O bus 136a can carry communications for up to 96 field devices, however a typical fieldbus segment is limited to connecting 16 devices. Thus, the number of wires coupled to the controller for the same number of field devices is significantly reduced.

The point-to-point or single-loop architectures shown in the illustrated example Offers several advantages and simplifications over traditional fieldbus solutions. For example, with field devices 1312a-c and 1314a-c wired as shown in the illustrated example, termination modules 1332a-f may provide power and power conditioning functionality to each field device (e.g., via field power controller 610). In this way the need for a separate DP/PA segment coupler 1322 and/or power supply 1324 shown in FIG. 13A is eliminated. Additionally or alternatively, in some examples, marshalling cabinet 1308 includes a substantially similar or identical power conditioner as power conditioner 218 (FIG. 2) to eliminate coupling to the separate DP/PA segments shown in FIG. 13A. controller 1322 and/or power supply 1324. Also, in such an example, since power is provided to the field devices in the example shown (e.g., within the marshalling cabinet 1308), the power requirements are lower than powering power along a typical fieldbus segment (e.g., due to cable length). voltage drop). Still further, in some examples, the termination modules 1332a-f (e.g., via corresponding site power controllers 610) provide short-circuit protection and current limiting for each of the cable junction points 1326a-c and 1328a-c, thereby The need for separate segment protectors 1330a-b is eliminated.

In addition, individually coupling field devices 1312a-c and 1314a-c to separate termination modules 1332a-f provides single loop integrity so that concerns over proper termination that are addressed in typical fieldbus architectures are no longer necessary . Moreover, the direct point-to-point connection between each field device 1312a-c and 1314a-c and the corresponding termination module 1332a-f significantly reduces the complexity and design effort involved in developing and implementing a typical fieldbus segment , because the signals from each field device are individually received and electronically processed or marshalled at the back end. Thus, implementations utilizing the teachings disclosed herein greatly reduce the cost of acquiring, configuring, and maintaining many of the components in a typical fieldbus architecture, as well as the time and expense of designing such an architecture and ensuring its proper operation. In other words, in some examples, Fieldbus compliant devices can be included in a process control system without requiring any DP/PA couplers and/or power supplies on the segment (e.g., other than marshalling cabinets 122 and/or termination modules 1332a-f except the power supply and/or power regulator), no segment protectors, no protocol-specific I/O cards, and no significant segment design effort.

Additionally, in some examples, termination modules 1332a-f provide advanced diagnostics (eg, via fieldbus diagnostic analyzer 624 of FIG. 6 ) without requiring separate advanced diagnostic modules 1325a-b. Also, in some examples, the diagnostics performed by the termination modules 1332a-f may be more reliable and/or robust than known advanced diagnostic modules since each termination module 1332a-f need only monitor a single site via a point-to-point connection. devices instead of multiple devices on a typical fieldbus segment.

Both Profibus PA and FF-H1 are fieldbus protocols with the same physical layer. Thus, in some examples, the termination modules 1332a-c associated with the field devices 1312a-c in the Profibus PA process area 1302 are the termination modules 1332d associated with the field devices 13142a-c in the FF-H1 process area 1304 -f is the same. In other words, in some examples, cable relay points 1326a-c connected to termination modules 1332a-c may be connected to termination modules 1332d-f, while cable relay points 1328a-c are connected to termination modules 1332a-c, Instead of termination modules 1332d-f. In some such examples, the termination modules 1332a-f include auto-sensing functionality to automatically detect the field devices 1312a-c and 1314a-c associated with the particular field devices 1312a-c to which the termination modules 1332a-f are connected. specific protocol (for example, Profibus PA or FF-H1). As a result, process control system engineers are free to use any fieldbus device they desire, regardless of the associated communication protocol (and can even mix devices compliant with different protocols), without the concern of having to design separate fieldbus segments or obtain an implementation The corresponding components required for this fieldbus.

In some examples, termination modules 1332a-f are configured to be intrinsically safe (eg, according to Fieldbus Intrinsically Safe Concept (FISCO)) to implement field devices 1312a-c and 1314a-c in hazardous environments. In such an example, the receptacle rail 1310 of the marshalling cabinet 1308 is also intrinsically safe. In some examples, the termination modules 1332a-f are constructed to be certified as energy-limited and/or have safety design specifications sufficient to meet Fieldbus Non-Incendive Concept (FNICO). In some such examples, the termination modules 1332a-f may comply with FNICO requirements even when plugged into a marshalling cabinet with receptacle rails that are not intrinsically safe.

Additionally or alternatively, in some examples, the termination modules described herein are configured to communicate with field devices based on other bus protocols (eg, other than Profibus PA or FF-H1). For example, in some examples, a termination module can be wired to a WirelessHART gateway to interface with one or more WirelessHART devices using the HART-IP application protocol. Additionally or alternatively, in some examples, wireless devices may be connected using other wireless technology standards, such as ISA (International Association of Automation) 100.11a or WIA-PA (Wireless Networks for Industrial Automation-Process Automation). In some examples, the termination modules described herein may be configured to interface with devices using Internet Protocol (IP)-based protocols, eg, using the 6TiSCH standard (IP version 6 of Time Slot Channel Hopping (TSCH)). In some examples, the termination module interfaces with the device using the Message Queue Telemetry Transport (MQTT) protocol. Furthermore, in some examples, safety field devices may be integrated using a tunneling protocol between the safety environment and the associated safety controller, eg, PROFIsafe (Profibus Safety).

14A and 14B illustrate an alternative exemplary embodiment of peer-to-peer communication of two FF-H1 compliant field devices 1402a-b communicatively coupled to corresponding termination modules 1404a-b. Exemplary termination modules 1404a-b are substantially similar or identical to termination modules 1332a-f described above. Although peer-to-peer communication between devices in the field is not provided for using the Profibus PA fieldbus protocol, such communication is possible when using the FF-H1 protocol, enabling communication with a controller (e.g., the control of FIG. 13A device 1306) has nothing to do with field control. In the illustrated example of FIG. 14A , termination modules 1404a-b are coupled to corresponding termination frame mounts 1406a-b ( FIG. 4 ) that are substantially similar or identical to mount 402, except that mounts 1406a-b are shown as There are four corresponding terminals 1408a-b. In the example shown, a pair of wires corresponding to each cable junction point 1410a-b of a field device 1402a-b is connected to a first pair of terminals 1408a-b, while a second pair of terminals from each base 1406a-b Corresponding terminals of 1408a-b are coupled to each other. In this manner, both of the field devices 1402a-b are communicatively coupled to each of the termination modules 1404a-b, and are also communicatively coupled to each other.

As shown in the illustrated example of FIG. 14A, direct coupling of individual field devices 1402a-b to each of the termination modules 1404a-b is possible because the termination modules 1404a-b are Devices 1402a-b provide independent power regulation functionality (eg, via field device controller 610). That is, the power conditioning provided by each of the termination modules 1404a-b is used to prevent a signal from one of the field devices (e.g., field device 1402a) from interrupting communication with another field device (e.g., field device 1402b) . But as mentioned above, in some examples, power regulation is provided by a single power regulator 218 for all field devices that are common on the same socket rail (eg, via injected power). In some such examples, field devices 1402a - b are communicatively coupled via segment protectors 1412 to termination modules 1404a - b as shown in FIG. 14B . That is, peer-to-peer communication between field devices 1402a-b is enabled through segment protector 1412, although each field device 1402a-b is still associated with a corresponding termination module 1404a-b. In addition, the segment protector 1412 prevents the power provided to each field device 1402a-b through its corresponding termination module 1404a-b from affecting the communication of any field device 1402a-b. In the illustrated examples of FIGS. 14A and 14B , additional wiring (eg, wiring for shielding and/or grounding) has been omitted for clarity.

The example method of FIG. 15 is described in conjunction with the example termination module 1332a of FIG. 13B. However, the exemplary method of FIG. 15 can be used to implement any other termination module. The flowchart of FIG. 15 is used to describe how the example termination module 1332a automatically detects the communication protocol associated with a corresponding field device (eg, field device 1312a ) connected to the termination module 1332a. Initially, the termination module 1332a determines (eg, via connection detector 806 of FIG. 8 ) whether a field device (eg, field device 1312a ) is connected to the termination module 1332a (block 1502 ). If termination module 1332a determines that field device 1312a (or any other field device) is not connected to termination module 1332a (block 1502), control remains at block 1502 until termination module 1332a determines that field device 1312a (or any other field device) ) is connected to the termination module 1332a.

If the termination module 1332a determines that the field device 1312a is connected to the termination module 1332a (block 1502), the termination module 1332a sends a request formatted according to a first communication protocol (e.g., Profibus PA) (e.g., via the field device of FIG. communications processor 620) (block 1504). In some examples, the request may correspond to a query requesting the field device to transmit its field device identification information, as described above in connection with block 1204 of FIG. 12 . The termination module 1332a then determines whether a response to the request has been received (block 1506). As described above in connection with block 1504, the request is formatted corresponding to a particular protocol. As a result, the only way field device 1312a can recognize a request, and therefore respond to a request, is if field device 1312a is associated with the same protocol. Accordingly, if the termination module 1332a determines that a response has been received (block 1506), the termination module 1332a specifies the communication protocol of the requested request being responded to as the protocol corresponding to the field device 1312a (block 1506). For example, if the first request is formatted according to the Profibus PA protocol and a response to the request is received, the communication protocol corresponding to field device 1312a is designated as Profibus PA.

If the termination module 1332a determines at block 1506 that no response to the request has been received, the termination module 1332a sends another request (e.g., via a field device communication processor) formatted according to another communication protocol (e.g., FF-H1). 620) (block 1508). Termination module 1332a then determines whether a response to the request has been received (block 1510). If the termination module 1332a determines that a response to the request has been received (block 1510), the termination module 1332a specifies the communication protocol of the responded request as the protocol corresponding to the field device 1312a (block 1516). If the termination module 1332a determines that no response to the request has been received (block 1510), the termination module 1332a then determines whether there are more communication protocols to test (e.g., other than Profibus PA and FF-H1 (e.g., HART) ). If more communication protocols exist, control returns to block 1508 to send another request formatted according to another communication protocol. If the termination module 1332a determines that there are no more communication protocols to test, the termination module 1332a generates an error message (block 1514). For example, an error message may indicate that field device 1312a is not responding and/or cannot recognize a communication protocol associated with field device 1312a.

After the termination module 1332a generates an error message (block 1514) or specifies the communication protocol of the requested request being responded to as the protocol corresponding to the field device 1312a (block 1516), the process of FIG. 15 ends and/or control returns to, for example, the call process or function.

FIG. 16 is a block diagram of an example processor system 1610 that may be used to implement the apparatus and methods described herein. For example, a processor system similar or identical to exemplary processor system 1610 may be used to implement workstation 102, controller 104, I/O card 132a, and/or termination modules 124a-c and 126a-c of FIG. 1A. Although the exemplary processor system 1610 is described below as including a number of peripherals, interfaces, chips, memory, etc., one or more of these elements may be selected from 132a and/or one or more of the termination modules 124a-c and 126a-c are omitted in other exemplary processor systems.

As shown in FIG. 16 , processor system 1610 includes processor 1612 coupled to interconnect bus 1614 . Processor 1612 includes register set or register space 1616, which is shown in FIG. Coupled to processor 1612. Processor 1612 may be any suitable processor, processing unit or microprocessor. Although not shown in FIG. 16 , system 1610 may be a multiprocessor system, and thus may include one or more additional processors, which are the same as or similar to processor 1612, and which are communicatively coupled to interconnection bus 1614 .

Processor 1612 of FIG. 16 is coupled to chipset 1618 , which includes memory controller 1620 and peripheral input/output (I/O) controller 1622 . Chipsets typically provide I/O and memory management functions, as well as a number of general and/or special purpose registers, timers, etc., which may be accessed or used by one or more processors coupled to chipset 1618, as is known. Memory controller 1620 performs the functions that enable processor 1612 (or processors, if multiple processors exist) to access system memory 1624 and mass storage memory 1625 .

System memory 1624 may include any desired type of volatile and/or nonvolatile memory, such as static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, read only memory (ROM), etc. . Mass storage memory 1625 may include any desired type of mass storage device. For example, if exemplary processor system 1610 is used to implement workstation 102 (FIG. 1A), mass storage memory 1625 may include hard drives, optical drives, tape storage devices, and the like. Alternatively, if exemplary processor system 1610 is used to implement controller 104, one of I/O cards 132a-b and 134a-b or one of termination modules 124a-c and 126a-c As modules, mass storage memory 1625 can include solid-state memory (e.g., flash memory, RAM memory, etc.), magnetic storage (e.g., a hard drive) or a memory suitable for controller 104, I/O cards 132a-b and 134a-b, or Any other memory for mass storage in termination modules 124a-c and 126a-c.

Peripheral I/O controller 1622 performs functions that enable processor 1612 to communicate with peripheral input/output (I/O) devices 1626 and 1628 and network interface 1630 via peripheral I/O bus 1632 . I/O devices 1626 and 1628 can be any desired type of I/O device, such as a keyboard, a display (e.g., a liquid crystal display (LCD), a cathode ray tube (CRT) display, etc.), a navigation device (e.g., a mouse, track balls, capacitive touchpads, joysticks, etc.), etc. Network interface 1630 may be, for example, an Ethernet device, an Asynchronous Transfer Mode (ATM) device, an 802.11 device, a DSL modem, a cable modem, a cellular modem, etc., that enables processor system 1610 to communicate with another processor system.

Although memory controller 1620 and/or I/O controller 1622 are shown in FIG. 16 as separate functional blocks within chipset 1618, the functions performed by these blocks may be integrated into a single semiconductor circuit, or two chipsets may be used. implemented by one or more individual integrated circuits.

Although particular methods, apparatus, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.

Claims (20)

1. A device comprising: terminal panel; a shared bus on the termination panel; and a plurality of sleds located on the termination panel along the shared bus, each of the sleds removably receives a module for communicating with a field device, and each of the sleds includes: A first physical interface communicatively coupled to a different type of field device and exchanging communications with one or more of the field devices via a plurality of different communication protocols, wherein the module automatically senses the communication protocol of the corresponding field device ;as well as A second physical interface communicatively couples the removably received module to the shared bus for communicating with a controller via the shared bus. 2. The apparatus of claim 1, wherein the second physical interface communicatively couples the removably received module to an input/output card in the controller. 3. The apparatus of claim 1 , wherein the first physical interface is operable as a digital interface for a first one of the modules and as a digital interface for a second one of the modules. Analog interface. 4. The apparatus of claim 1, wherein the dissimilar field devices include valves, actuators, and sensors. 5. The apparatus of claim 1, wherein each of the mounts is configured to receive a different type of the module. 6. The apparatus of claim 5, wherein the different types of modules include analog input modules, analog output modules, digital input modules, and digital output modules. 7. A system comprising: A base that removably receives modules that can be selected from different types of modules that communicate with different types of field devices, the base includes: a first physical interface communicatively coupling the module to at least one of the different types of field devices, wherein the module automatically senses the communication protocol of the corresponding field device; and a second physical interface communicatively coupling the module to a controller, wherein insertion of the module into the base forms a connection between the module and the first physical interface and the second physical interface ; a shared bus carrying communications between the controller, the base, and a plurality of second bases in communication with the shared bus; and a transceiver communicatively coupled to the base and the plurality of second bases via the shared bus, the transceiver exchanging communications between the shared bus and the controller. 8. The system of claim 7, wherein the first physical interface uses a plurality of different communication protocols between any of the different types of modules and one or more of the different types of field devices Exchange information between field devices. 9. The system of claim 8, wherein the information is at least one of temperature measurement information, pressure measurement information, fluid flow measurement information, or valve actuator control information. 10. The system of claim 7, wherein the transceiver is configured to communicate with an input/output card in the controller. 11. The system of claim 7, wherein the transceiver is configured to communicate with the controller via an Ethernet protocol. 12. The system of claim 7, wherein the transceiver is a wireless transceiver. 13. The system of claim 7, wherein the mount is configured to be removably mounted to a socket rail to communicatively couple the mount to the transceiver. 14. A system comprising: a base that removably receives a module selectable from different types of modules that communicate with different types of field devices, wherein the module automatically senses the communication protocol of the corresponding field device; A first physical interface and a second physical interface formed in the base, the first physical interface communicatively coupling the module to at least one of the different types of field devices, and the second a physical interface communicatively couples the module to the controller; a shared bus in communication with the base and a plurality of second bases, the shared bus carrying communications between the controller, the base, and the plurality of second bases; and a transceiver communicatively coupled to the base and the plurality of second bases via the shared bus, the transceiver exchanging communications between the shared bus and the controller. 15. The system of claim 14, wherein the first physical interface uses a plurality of different communication protocols between any of the different types of modules and one or more of the different types of field devices Exchange information between field devices. 16. The system of claim 15, wherein the information is at least one of temperature measurement information, pressure measurement information, fluid flow measurement information, or valve actuator control information. 17. The system of claim 14, wherein the transceiver is configured to communicate with an input/output card in the controller. 18. The system of claim 14, wherein the transceiver is configured to communicate with the controller via an Ethernet protocol. 19. The system of claim 14, wherein the transceiver is a wireless transceiver. 20. The system of claim 14, wherein the mount is configured to be removably mounted to a socket rail to communicatively couple the mount to the transceiver.

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