WO2017071755A1 - A mobile i/o module communications device and a system for process control system cable configuration - Google Patents

A mobile i/o module communications device and a system for process control system cable configuration Download PDF

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Publication number
WO2017071755A1
WO2017071755A1 PCT/EP2015/075086 EP2015075086W WO2017071755A1 WO 2017071755 A1 WO2017071755 A1 WO 2017071755A1 EP 2015075086 W EP2015075086 W EP 2015075086W WO 2017071755 A1 WO2017071755 A1 WO 2017071755A1
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WO
WIPO (PCT)
Prior art keywords
module
field device
mobile
cable
field
Prior art date
Application number
PCT/EP2015/075086
Other languages
French (fr)
Inventor
Joerg Schubert
Johan HOLTMANN
Mikael Rudin
Robert Norberg
Stefan Bollmeyer
Original Assignee
Abb Schweiz Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Abb Schweiz Ag filed Critical Abb Schweiz Ag
Priority to PCT/EP2015/075086 priority Critical patent/WO2017071755A1/en
Publication of WO2017071755A1 publication Critical patent/WO2017071755A1/en

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Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/04Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G05B19/0423Input/output
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/20Pc systems
    • G05B2219/25Pc structure of the system
    • G05B2219/25428Field device

Definitions

  • the present disclosure generally relates to control systems such as process control systems. In particular, it relates to the procedure of configuring cable connections between field devices and I/O modules.
  • Process control systems typically comprise one or more process controllers communicatively coupled to an operator workstation.
  • the one or more process controller is furthermore communicatively coupled to at least one field device.
  • the communication between the process controller and the field device(s) may be provided via an analog, a digital or a hybrid communication protocol.
  • a number of input/output (I/O) modules are arranged in the communication path between a process controller and the field devices.
  • the I/O modules form an interface which enables communication between process controllers and field devices.
  • the field devices such as device controllers, valve actuators, valve
  • the field devices send signals to the process controller (s), for example in the form of process variable values, wherein the process controller(s) uses the signal information to implement a control routine, and generate control signals that are sent to the field devices, e.g. to actuators, to control the operation of the process.
  • a connection between the process control system and the field devices has traditionally been configured, or set up, by means of manual labour, typically carried out by two persons. One is located in the electrical room and the other one in the process environment among the field devices. Connections of cables from I/O modules to field devices have been noted on paper for later basis of marshalling in the process control system. Marshalling refers to the process of defining which I/O module is connected to which field device.
  • a more modern approach utilises the functionality of smart field devices, i.e. a field device that includes intelligence and that can be programmed to contain a field device ID which it can send to an I/O module.
  • DCS Distributed Control Systems
  • US2009319062 discloses an apparatus for automatically registering the topology of individual components of a process installation in automation technology.
  • a radio tag is associated with each field device.
  • Each field device in the process installation is provided with a relatively low cost, writable and readable, radio tag.
  • a radio tag may contain information about the address or the so-called "tag" of the associated field device, wherein such field device is reached via this address.
  • Stored on the radio tag is topology-relevant information of the corresponding field device.
  • a radio tag reader is provided which registers the topology-relevant information of the radio tags and forwards it to a superordinated control unit.
  • US2009319062 discloses that the topology-relevant information is sent to a superordinated control unit, the method does not provide a link between field devices and I/O modules to which they are connected. Thus, unless the field devices are smart field devices, no defined connection between the control application and field devices can be established automatically.
  • an object of the present disclosure is to provide a mobile I/O module communications device and a system for facilitating the cable configuration procedure of a process control system containing non-smart and/or binary field devices.
  • a mobile I/O module communications device for setting up cable connections between field devices and I/O modules in a process control system
  • the mobile I/O module communications device comprises: a cable interface configured to physically connect to an I/O module cable that connects an I/O module with a field device, and processing circuitry configured to obtain data field device ID uniquely identifying a field device distinct from the mobile I/O module communications device, wherein the processing circuitry is configured to send the field device ID to an I/O channel of an I/O module via an I/O module cable connected to the cable interface and to the I/O module.
  • the field device ID of a field device is obtained by the mobile I/O module communications device.
  • the mobile I/O module communications device is physically connected to an I/O module, and in particular to a specific I/O channel of an I/O module.
  • the obtained field device ID may be sent to the I/O module connected to the field device in question by means of the cable interface.
  • non-smart field devices and binary devices such as mechanical switches, proximity switches and valves, and smart field devices that have not been programmed with a digital field device ID tag, may be associated with corresponding I/O modules.
  • the I/O modules may subsequently send the received field device ID together with the I/O channel ID of the receiving I/O module, the I/O module ID and/or the I/O cabinet ID to an engineering tool or to a controller to thereby enable setting up the process control topology.
  • One embodiment comprises a communications unit configured to receive the field device ID from an external mobile ID tag reading device.
  • One embodiment comprises an ID tag reader arranged to read a field device ID tag, and wherein the processing circuitry is arranged to obtain the field device ID from the field device ID tag.
  • the cable interface comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device physically to an I/O module cable to thereby enable the cable interface to send the field device ID via the cable to an I/O channel of an I/O module connected to the I/O module cable.
  • modulation circuitry configured to feed the cable interface with a signal that includes the field device ID, which enables the cable interface to send the field device ID to an I/O module connected to the cable interface by means of an I/O module cable.
  • a system for setting up cable connections between field devices and I/O modules in a process control system comprising a mobile I/O module communications device comprising: a cable interface configured to physically connect to an I/O module cable that connects an I/O module with a field device, and processing circuitry configured to obtain data field device ID uniquely identifying a field device distinct from the mobile I/O module communications device; an I/O module having an I/O channel, wherein the I/O module comprises: a channel communications interface enabling the I/O channel to communicate with a field device, which channel communications interface is physically connectable to the cable interface of the mobile I/O module communications device by means of an I/O module cable, wherein the processing circuitry is configured to send the field device ID to the I/O channel of the I/O module via an I/O module cable connected to the cable interface and to the I/O module, and wherein the channel communications interface is configured to receive the field device ID from the mobile I/O module communications device.
  • the I/O module comprises a storage unit, wherein the I/O module is configured to store the ID tag in the storage unit, thereby providing a link between an I/O channel ID of the I/O channel and the field device ID.
  • the channel communications interface is configured to send the field device ID tag and at least one of a corresponding I/O channel ID of the I/O channel, I/O module ID and I/O cabinet ID to one of an engineering tool and a controller.
  • the mobile I/O module communications device comprises modulation circuitry configured to feed the cable interface with a signal that includes the field device ID, which enables the cable interface to send the field device ID to an I/O module connected to the cable interface by means of an I/O module cable.
  • One embodiment comprises a mobile ID tag reading device configured to read field device ID tags provided physically on field devices, and to send field device ID extracted from a field device ID tag to the mobile I/O module communications device.
  • the mobile ID tag reading device is configured to send a command to the mobile I/O module communications device to send the received field device ID to an I/O module via the cable interface.
  • the mobile I/O module communications device comprises a communications unit configured to receive the field device ID from the mobile ID tag reading device.
  • the mobile I/O module communications device comprises an ID tag reader arranged to read a field device ID tag physically arranged on a field device, wherein the processing circuitry is configured to extract the field device ID from the field device ID tag.
  • the cable interface comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device physically to an I/O module cable to thereby enable the cable interface to send the field device ID via the I/O module cable to an I/O channel of an I/O module connected to the I/O module cable.
  • Fig. 1 schematically shows a block diagram of an example of a mobile I/O module communications device
  • Fig. 2 shows a system including the mobile I/O module communications device in Fig. ⁇ for setting up cable connections between field devices and I/O modules in a process control system
  • Fig. 1 schematically shows a block diagram of an example of a mobile I/O module communications device
  • Fig. 2 shows a system including the mobile I/O module communications device in Fig. ⁇ for setting up cable connections between field devices and I/O modules in a process control system
  • Fig. 3 shows a process control system including the system in Fig. 2.
  • the mobile I/O module communications device disclosed herein is designed to facilitate configuration of the wiring between I/O modules, or I/O cards, and field devices in a process control system.
  • Each field device that is to be configured utilising the mobile I/O module communications device may for this purpose for example have unique physical field device ID tag provided on it.
  • Such a physical field device ID tag may for example be a bar code, a QR code, an image showing the field device ID or an RFID tag.
  • the mobile I/O module communications device is configured to obtain a field device ID contained in or associated with the field device ID tag, and to send the field device ID to an I/O module that is physically connected to the mobile I/O module communications device via an I/O module cable.
  • This is the same I/O module cable that during operation connects the I/O module and the particular field device.
  • the I/O module will receive the field device ID, and a connection between the I/O channel that received the field device ID and the field device may be established.
  • This may for example be established in an engineering tool to which the I/O module may be connected and to which the I/O module may send the field device ID.
  • the engineering tool may subsequently load the I/O module-field device connection into a controller which is to communicate with the field device in operation.
  • Fig. l depicts an example of a mobile I/O module communications device ⁇ for setting up cable connections between field devices and I/O modules in a process control system.
  • the mobile I/O module communications device l comprises processing circuitry 3 configured to obtain a field device ID.
  • This field device ID is distinct from any ID of the I/O module communications device 1 and may for example be contained in a field device ID tag that is physically provided on a field device.
  • the processing circuitry 3 uses any combination of one or more of a suitable central processing unit (CPU), multiprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC), field programmable gate arrays (FPGA) etc., capable of executing any herein disclosed operations.
  • CPU central processing unit
  • DSP digital signal processor
  • ASIC application specific integrated circuit
  • FPGA field programmable gate arrays
  • the mobile I/O module communications device 1 furthermore comprises a cable interface 9.
  • the cable interface 9 is configured to be physically connected to an I/O module cable which normally connects an I/O module and a field device.
  • the cable interface 9 is hence arranged to provide a mechanical connection between an I/O module cable and mobile I/O module communications device 1.
  • the cable interface 9 may for example be provided by an electromagnetic coupling, such as a capacitive coupling, between the cable interface 9 and the I/O module cable, or by electrical coupling.
  • the cable interface 9 may for example be configured to be connected to that end of the I/O module cable which usually is connected to a field device.
  • the cable interface 9 may comprise a cable attachment member arranged to temporarily connect the mobile I/O module communications device 1 physically to an I/O module cable.
  • the cable attachment member may for example include a clamp for clamping the cable interface 9 around an I/O module cable.
  • the cable attachment member may comprise a cable connector to which an I/O module cable may be connected.
  • the mobile I/O module communications device 1 may according to one variation comprise a communications unit 5 configured to communicate with an external mobile ID tag reading device.
  • the communications device 1 may thereby receive the field device ID from the mobile ID tag reading device. In this manner the processing circuitry 3 is able to obtain the field device ID of a field device.
  • the communications unit 5 may be configured to provide wireless communication between the mobile ID tag reading device and the mobile I/O module communications device 1.
  • the communications unit 5 may be configured to provide wired communication between the mobile ID tag reading device and the mobile I/O module communications device 1.
  • the mobile I/O module communications device 1 may according to one variation comprise an ID tag reader arranged to read a field device ID tag, for example physically arranged on a field device. In this case, the mobile I/O module communications device 1 would not have to communicate with an external mobile ID tag reading device to obtain the field device ID obtained from a physical tag on a field device.
  • the processing circuitry 3 may in this case be configured to obtain the field device ID by extracting it from the field device ID tag.
  • the ID tag reader may for example be an RFID
  • the mobile I/O module communications device 1 may further comprise modulation circuitry 7 configured to feed the cable interface 9 with a signal that includes the field device ID.
  • the modulation circuitry 7 is hence operatively connected to the processing circuitry 3.
  • the cable interface 9 may thereby send the field device ID through an I/O module cable to an I/O module connected to the cable interface 9.
  • the modulation circuitry 7 may for example be configured to create short circuits in the cable loop formed by an I/O module, a field device, and the I/O module cable connected between the I/O module and the field device, in accordance with a suitable encoding method.
  • the modulation circuitry 9 may be configured to impose a high frequency transmission signal into an I/O module cable.
  • An input I/O channel is an I/O channel of an I/O module which is configured to receive data from field devices, e.g. from sensors.
  • An output I/O channel is an I/O channel of an I/O module which is configured to send data to field devices, e.g. control signals to actuators.
  • Fig. 2 shows an example of a system 11 for setting up cable connections between field devices and I/O modules in a process control system.
  • the system 11 comprises the mobile I/O module communications device 1 and an I/O module 15.
  • the I/O module 15 is arranged to be mounted in an I/O cabinet.
  • the I/O module 15 is configured to be connected to an I/O module slot in the I/O cabinet.
  • the I/O cabinet may comprise a plurality of I/O modules 15, each being installed in a respective I/O module slot and each I/O module providing one or more unique I/O channels.
  • the I/O module 15 is connectable to a controller 19 and to an engineering tool ET via the I/O module slot.
  • the engineering tool is an application that for example may be installed on a personal computer, and comprises control program code that can be edited by a user and which can be loaded into the controller 19 for controlling field devices of a process control system.
  • the I/O module 15 comprises a channel communications interface 15a which enables the I/O channel of the I/O module to communicate with a field device.
  • the channel communications interface 15a is configured to be connected to an I/O module cable 17, to thereby connect the I/O module 15 to the field device 13.
  • the I/O module 15 is able to physically connect with the cable interface 9 of the mobile I/O module communications device 1 by physically connecting the cable interface 9 of the mobile I/O module communications device 1 to the I/O module cable 17 connected to the I/O module 15.
  • the I/O module cable 17 is connected to both the field device 13 and the I/O module 15 during operation.
  • the I/O module cable 17 may or may not be connected to the field device 13 when utilising the mobile I/O module communications device 1.
  • the mobile I/O module communications device 1 may thereby send the field device ID to the I/O module 15, and in particular to the I/O channel connected to the field device 13.
  • the I/O module 15 may also include a storage unit 15b which contains an I/O channel ID of the I/O channel, or of each I/O channel in case the I/O module 15 has more than one I/O channel.
  • the storage unit 15b may according to one variation be arranged to store a field device ID sent from the mobile I/O module communications device 1 to the I/O module 15.
  • the I/O module 15 is configured to send the received field device ID to the engineering tool ET and/or to the controller 19.
  • the I/O module 15 may also be configured to send the I/O channel ID together with the field device ID, and/or at least one of the I/O module ID and the I/O cabinet ID.
  • field device 13 is provided with a field device ID tag 13b.
  • the field device ID tag 13b may be physically arranged on the field device 13.
  • the field device ID tag may for example be an image showing the field device ID, an RFID tag, a bar code, a QR code or similar.
  • the mobile I/O module communications device 1 obtains the field device ID contained in the field device ID tag.
  • the field device tag could alternatively be provided in a physical list, on a blueprint of the plant, including the position of all field devices, or a digital list for example stored in the mobile I/O communications device.
  • the mobile I/O module communications device 1 may for example be configured to obtain the field device ID by itself, reading the field device ID tag 13b or it may be obtained from a mobile ID tag reading device 21, both examples being illustrated in Fig. 2.
  • the mobile ID tag reading device 21 may for example be a smart phone or a tablet computer provided with a field device ID tag reading application.
  • the mobile ID tag reading device 21 may be configured to send the field device ID wirelessly, or via a wired connection, for example by attaching an adapter to the mobile ID tag reading device 21, which adapter enables the set up of a wired connection between the mobile ID tag reading device 21 and the mobile I/O module communications device 1.
  • the mobile I/O module communications device 1 may send the field device ID to the I/O module 15.
  • the mobile I/O module communications device 1 may in particular send the field device ID after the mobile I/O module communications device 1 has been physically connected to the I/O module cable 17.
  • the mobile ID tag reading device 21 may send a command to the mobile I/O module communications device 1 that the mobile I/O module communications device 1 shall send the field device ID to the I/O module 15.
  • the mobile ID tag reading device may include a user interface, which enables a user to determine when to send the command to the mobile I/O module communications device 1.
  • the I/O module 15 may according to one variation be configured to send an acknowledgement, which contains the I/O channel ID and the I/O module address, i.e. the I/O module slot number of the I/O cabinet, back to the mobile I/O module communications device 1.
  • the mobile I/O module communications device 1 may then be configured to send this information to the engineering tool ET for setting up the connection between the field device and the I/O module in question.
  • Fig. 3 shows an example of a process control system 23 comprising a controller 19 and a first I/O cabinet 16a comprising a plurality of I/O modules 15-1 to 15-3 installed therein, and field devices 13-1 to 13-3, each field device 13-1 to 13-3 being physically connected to a respective I/O module 15-1 to 15-3 by means of I/O module cables.
  • each field device 13-1 to 13-3 is provided with a respective physical field device ID tag 25-1 to 25-3.
  • the process control system 23 furthermore comprises a second I/O cabinet 16b comprising a plurality of I/O modules 15-4 to 15-6 installed therein, and field devices 13-4 to 13-6, each field device 13-4 to 13-6 being connected to a respective I/O module 15-4 to 15-6 by means of I/O module cables.
  • each field device 13-4 to 13-6 is provided with a respective physical field device ID tag 25-4 to 25-6.
  • the field devices 13-1 to 13-6 are assumed to be non-smart field devices or binary devices.
  • the process control system 23 also comprises an engineering tool ET.
  • the entire process control system 23 is communicatively connected via a communications network N.
  • a user carries the mobile I/O module communications device 1 in the process control environment.
  • the user may optionally also carry a mobile ID tag reading device 21.
  • the user approaches field device 13-1 and reads the field device ID tag provided on the field device 13-1.
  • the field device ID contained therein is thereby obtained, either by the mobile I/O module communications device 1 or by the mobile ID tag reading device 21.
  • the mobile ID tag reading device 21 sends the field device ID to the mobile I/O module communications device 1.
  • the user physically connects the cable interface 9 of the mobile I/O module communications device 1 to I/O module cable 17-1.
  • the cable interface 9 may be arranged e.g. around the I/O module cable 17-1 to thereby obtain an electromagnetic coupling, or an electrical coupling.
  • the field device ID may be sent to I/O module 15-1 via the I/O module cable 17-1.
  • the storage unit 15a of the I/O module 15-1 can thus store the field device ID and/or it may send it to the engineering tool ET or to the controller 19.
  • the I/O module 15-1 also sends at least one of the I/O channel ID of the I/O channel that received the field device ID, the I/O module ID of the receiving I/O module 15-1 and the I/O cabinet ID of the receiving I/O cabinet 16a.
  • a connection between field device 15-1 and the I/O module 15- 1 to which field device 13-1 is connected to may be established at the engineering tool level or at the controller level. This may for example be utilised when adapting the control program code in accordance with the topology of the process control system 23.
  • the user disconnects the cable interface 9 from the I/O module cable 17-1 and repeats the procedure with the remaining field devices 13-2 to 13-6 and corresponding I/O modules 15-2 to 15-6. In this manner the connections between all I/O modules and all field devices, including non-smart and binary field devices, can be obtained.
  • this procedure would not have to be carried out with those field devices. It should be noted that this procedure may be performed also in case one or more I/O module has a plurality of I/O channels; each I/O channel is also in this case connected to a unique field device, and each I/O channel has a unique I/O channel ID. The process may be carried out before or after the I/O module is connected to the rest of the process control system.
  • the field device ID tag could be selected from a list of field devices each having a unique field device ID tag.
  • the mobile I/O module communications device could be provided with a user interface, and contain the list of field devices included in the plant installation such that a user could select a field device in the list whereby the processing circuitry would obtain the field device ID to be sent to an I/O module.
  • the mobile ID tag reading device could be provided with the list, from which a user could select field device ID tags and send them to the mobile I/O module communications device.
  • the field device ID tag may be provided on plant blueprint or in a list on a piece of paper carried by the user.
  • the field device ID tag could then be fed e.g. manually into the mobile I/O module communications device via a user interface or via the mobile ID tag reading device.

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Abstract

The present disclosure relates to a mobile I/O module communications device (1) for setting up cable connections between field devices (13) and I/O modules (15) in a process control system (23). The mobile I/O module communications device (1) comprises a cable interface (9) configured to physically connect to an I/O module cable (17) that connects an I/O module (15) with a field device (13), and processing circuitry (3) configured to obtain a field device ID uniquely identifying a field device distinct from the mobile I/O module communications device (1). The processing circuitry (3) is configured to send the field device ID to an I/O channel of an I/O module (15) via an I/O module cable (17) connected to the cable interface (9) and to the I/O module (15). The present disclosure furthermore relates to a system including a mobile I/O module communications device.

Description

A MOBILE I/O MODULE COMMUNICATIONS DEVICE AND A SYSTEM FOR PROCESS CONTROL SYSTEM CABLE CONFIGURATION
TECHNICAL FIELD
The present disclosure generally relates to control systems such as process control systems. In particular, it relates to the procedure of configuring cable connections between field devices and I/O modules.
BACKGROUND
Process control systems typically comprise one or more process controllers communicatively coupled to an operator workstation. The one or more process controller is furthermore communicatively coupled to at least one field device. The communication between the process controller and the field device(s) may be provided via an analog, a digital or a hybrid communication protocol. Normally, a number of input/output (I/O) modules are arranged in the communication path between a process controller and the field devices. The I/O modules form an interface which enables communication between process controllers and field devices.
The field devices, such as device controllers, valve actuators, valve
positioners, switches and transmitters, perform functions within the process controlled by the process control system. The field devices send signals to the process controller (s), for example in the form of process variable values, wherein the process controller(s) uses the signal information to implement a control routine, and generate control signals that are sent to the field devices, e.g. to actuators, to control the operation of the process.
A connection between the process control system and the field devices has traditionally been configured, or set up, by means of manual labour, typically carried out by two persons. One is located in the electrical room and the other one in the process environment among the field devices. Connections of cables from I/O modules to field devices have been noted on paper for later basis of marshalling in the process control system. Marshalling refers to the process of defining which I/O module is connected to which field device.
A more modern approach utilises the functionality of smart field devices, i.e. a field device that includes intelligence and that can be programmed to contain a field device ID which it can send to an I/O module.
Once the correct physical mounting and the cable labelling of a device has been performed Distributed Control Systems (DCS) utilise a communication protocol such as the HART protocol to read tag information from the smart field devices to the system. The tag information of each smart field device can be used for association with the corresponding I/O channel. With proper system functionality in place this means that the application engineering can be made in parallel to the hardware installation, and when the system is commissioned and the application is downloaded on site, the application finds and configures the correct field device including the needed loop check without any manual configuration.
US2009319062 discloses an apparatus for automatically registering the topology of individual components of a process installation in automation technology. A radio tag is associated with each field device. Each field device in the process installation is provided with a relatively low cost, writable and readable, radio tag. A radio tag may contain information about the address or the so-called "tag" of the associated field device, wherein such field device is reached via this address. Stored on the radio tag is topology-relevant information of the corresponding field device. A radio tag reader is provided which registers the topology-relevant information of the radio tags and forwards it to a superordinated control unit.
SUMMARY
Although US2009319062 discloses that the topology-relevant information is sent to a superordinated control unit, the method does not provide a link between field devices and I/O modules to which they are connected. Thus, unless the field devices are smart field devices, no defined connection between the control application and field devices can be established automatically.
In view of the above, an object of the present disclosure is to provide a mobile I/O module communications device and a system for facilitating the cable configuration procedure of a process control system containing non-smart and/or binary field devices.
Hence, according to a first aspect of the present disclosure there is provided a mobile I/O module communications device for setting up cable connections between field devices and I/O modules in a process control system, wherein the mobile I/O module communications device comprises: a cable interface configured to physically connect to an I/O module cable that connects an I/O module with a field device, and processing circuitry configured to obtain data field device ID uniquely identifying a field device distinct from the mobile I/O module communications device, wherein the processing circuitry is configured to send the field device ID to an I/O channel of an I/O module via an I/O module cable connected to the cable interface and to the I/O module.
When configuring, or setting up, the cable connections in a process control system, between I/O modules and field devices, the field device ID of a field device is obtained by the mobile I/O module communications device. In use, the mobile I/O module communications device is physically connected to an I/O module, and in particular to a specific I/O channel of an I/O module.
By means of the mobile I/O module communications device, the obtained field device ID may be sent to the I/O module connected to the field device in question by means of the cable interface. In this manner, non-smart field devices and binary devices such as mechanical switches, proximity switches and valves, and smart field devices that have not been programmed with a digital field device ID tag, may be associated with corresponding I/O modules. The I/O modules may subsequently send the received field device ID together with the I/O channel ID of the receiving I/O module, the I/O module ID and/or the I/O cabinet ID to an engineering tool or to a controller to thereby enable setting up the process control topology. By collecting the field device ID from all of the field devices the configuration procedure may be greatly facilitated. The possibility of true plug-and-play engineering may thereby be provided, expediting commissioning
significantly. Today, this technology is not available for non-smart or binary field devices. One embodiment comprises a communications unit configured to receive the field device ID from an external mobile ID tag reading device.
One embodiment comprises an ID tag reader arranged to read a field device ID tag, and wherein the processing circuitry is arranged to obtain the field device ID from the field device ID tag. According to one embodiment the cable interface comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device physically to an I/O module cable to thereby enable the cable interface to send the field device ID via the cable to an I/O channel of an I/O module connected to the I/O module cable. One embodiment comprises modulation circuitry configured to feed the cable interface with a signal that includes the field device ID, which enables the cable interface to send the field device ID to an I/O module connected to the cable interface by means of an I/O module cable.
According to a second aspect of the present disclosure there is provided a system for setting up cable connections between field devices and I/O modules in a process control system, wherein the system comprises a mobile I/O module communications device comprising: a cable interface configured to physically connect to an I/O module cable that connects an I/O module with a field device, and processing circuitry configured to obtain data field device ID uniquely identifying a field device distinct from the mobile I/O module communications device; an I/O module having an I/O channel, wherein the I/O module comprises: a channel communications interface enabling the I/O channel to communicate with a field device, which channel communications interface is physically connectable to the cable interface of the mobile I/O module communications device by means of an I/O module cable, wherein the processing circuitry is configured to send the field device ID to the I/O channel of the I/O module via an I/O module cable connected to the cable interface and to the I/O module, and wherein the channel communications interface is configured to receive the field device ID from the mobile I/O module communications device.
According to one embodiment the I/O module comprises a storage unit, wherein the I/O module is configured to store the ID tag in the storage unit, thereby providing a link between an I/O channel ID of the I/O channel and the field device ID.
According to one embodiment the channel communications interface is configured to send the field device ID tag and at least one of a corresponding I/O channel ID of the I/O channel, I/O module ID and I/O cabinet ID to one of an engineering tool and a controller. According to one embodiment the mobile I/O module communications device comprises modulation circuitry configured to feed the cable interface with a signal that includes the field device ID, which enables the cable interface to send the field device ID to an I/O module connected to the cable interface by means of an I/O module cable. One embodiment comprises a mobile ID tag reading device configured to read field device ID tags provided physically on field devices, and to send field device ID extracted from a field device ID tag to the mobile I/O module communications device. According to one embodiment the mobile ID tag reading device is configured to send a command to the mobile I/O module communications device to send the received field device ID to an I/O module via the cable interface.
According to one embodiment the mobile I/O module communications device comprises a communications unit configured to receive the field device ID from the mobile ID tag reading device.
According to one embodiment the mobile I/O module communications device comprises an ID tag reader arranged to read a field device ID tag physically arranged on a field device, wherein the processing circuitry is configured to extract the field device ID from the field device ID tag.
According to one embodiment the cable interface comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device physically to an I/O module cable to thereby enable the cable interface to send the field device ID via the I/O module cable to an I/O channel of an I/O module connected to the I/O module cable.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a/an/the element, apparatus, component, means, etc. are to be interpreted openly as referring to at least one instance of the element, apparatus, component, means, etc., unless explicitly stated otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
The specific embodiments of the inventive concept will now be described, by way of example, with reference to the accompanying drawings, in which: Fig. 1 schematically shows a block diagram of an example of a mobile I/O module communications device; Fig. 2 shows a system including the mobile I/O module communications device in Fig. ι for setting up cable connections between field devices and I/O modules in a process control system; and
Fig. 3 shows a process control system including the system in Fig. 2. DETAILED DESCRIPTION
The inventive concept will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplifying
embodiments are shown. The inventive concept may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept to those skilled in the art. Like numbers refer to like elements throughout the description.
The mobile I/O module communications device disclosed herein is designed to facilitate configuration of the wiring between I/O modules, or I/O cards, and field devices in a process control system. Each field device that is to be configured utilising the mobile I/O module communications device may for this purpose for example have unique physical field device ID tag provided on it. Such a physical field device ID tag may for example be a bar code, a QR code, an image showing the field device ID or an RFID tag.
The mobile I/O module communications device is configured to obtain a field device ID contained in or associated with the field device ID tag, and to send the field device ID to an I/O module that is physically connected to the mobile I/O module communications device via an I/O module cable. This is the same I/O module cable that during operation connects the I/O module and the particular field device. Thereby, the I/O module will receive the field device ID, and a connection between the I/O channel that received the field device ID and the field device may be established. This may for example be established in an engineering tool to which the I/O module may be connected and to which the I/O module may send the field device ID. The engineering tool may subsequently load the I/O module-field device connection into a controller which is to communicate with the field device in operation.
Fig. l depicts an example of a mobile I/O module communications device ι for setting up cable connections between field devices and I/O modules in a process control system.
The mobile I/O module communications device l comprises processing circuitry 3 configured to obtain a field device ID. This field device ID is distinct from any ID of the I/O module communications device 1 and may for example be contained in a field device ID tag that is physically provided on a field device.
The processing circuitry 3 uses any combination of one or more of a suitable central processing unit (CPU), multiprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC), field programmable gate arrays (FPGA) etc., capable of executing any herein disclosed operations.
The mobile I/O module communications device 1 furthermore comprises a cable interface 9. The cable interface 9 is configured to be physically connected to an I/O module cable which normally connects an I/O module and a field device. The cable interface 9 is hence arranged to provide a mechanical connection between an I/O module cable and mobile I/O module communications device 1.
Transmission of the field device ID from the mobile I/O module
communications device 1 to an I/O module by means of the cable interface 9 may for example be provided by an electromagnetic coupling, such as a capacitive coupling, between the cable interface 9 and the I/O module cable, or by electrical coupling. In the latter case, the cable interface 9 may for example be configured to be connected to that end of the I/O module cable which usually is connected to a field device. The cable interface 9 may comprise a cable attachment member arranged to temporarily connect the mobile I/O module communications device 1 physically to an I/O module cable. The cable attachment member may for example include a clamp for clamping the cable interface 9 around an I/O module cable. Alternatively, the cable attachment member may comprise a cable connector to which an I/O module cable may be connected.
The mobile I/O module communications device 1 may according to one variation comprise a communications unit 5 configured to communicate with an external mobile ID tag reading device. The mobile I/O module
communications device 1 may thereby receive the field device ID from the mobile ID tag reading device. In this manner the processing circuitry 3 is able to obtain the field device ID of a field device. The communications unit 5 may be configured to provide wireless communication between the mobile ID tag reading device and the mobile I/O module communications device 1.
Alternatively, the communications unit 5 may be configured to provide wired communication between the mobile ID tag reading device and the mobile I/O module communications device 1.
The mobile I/O module communications device 1 may according to one variation comprise an ID tag reader arranged to read a field device ID tag, for example physically arranged on a field device. In this case, the mobile I/O module communications device 1 would not have to communicate with an external mobile ID tag reading device to obtain the field device ID obtained from a physical tag on a field device. The processing circuitry 3 may in this case be configured to obtain the field device ID by extracting it from the field device ID tag. The ID tag reader may for example be an RFID
reader/interrogator, a QR code reader, a bar code reader, OCR application etc. or a combination thereof.
The mobile I/O module communications device 1 may further comprise modulation circuitry 7 configured to feed the cable interface 9 with a signal that includes the field device ID. The modulation circuitry 7 is hence operatively connected to the processing circuitry 3. The cable interface 9 may thereby send the field device ID through an I/O module cable to an I/O module connected to the cable interface 9. The modulation circuitry 7 may for example be configured to create short circuits in the cable loop formed by an I/O module, a field device, and the I/O module cable connected between the I/O module and the field device, in accordance with a suitable encoding method. According to another alternative the modulation circuitry 9 may be configured to impose a high frequency transmission signal into an I/O module cable. With high frequency is here meant a frequency that is substantially higher than the frequency of normal signal transmission through an I/O module cable, so as not to interfere with the normal signal transmission. These methods could be used both for input I/O channels and for output I/O channels. An input I/O channel is an I/O channel of an I/O module which is configured to receive data from field devices, e.g. from sensors. An output I/O channel is an I/O channel of an I/O module which is configured to send data to field devices, e.g. control signals to actuators.
Fig. 2 shows an example of a system 11 for setting up cable connections between field devices and I/O modules in a process control system. The system 11 comprises the mobile I/O module communications device 1 and an I/O module 15. The I/O module 15 is arranged to be mounted in an I/O cabinet. The I/O module 15 is configured to be connected to an I/O module slot in the I/O cabinet. The I/O cabinet may comprise a plurality of I/O modules 15, each being installed in a respective I/O module slot and each I/O module providing one or more unique I/O channels. The I/O module 15 is connectable to a controller 19 and to an engineering tool ET via the I/O module slot. The engineering tool is an application that for example may be installed on a personal computer, and comprises control program code that can be edited by a user and which can be loaded into the controller 19 for controlling field devices of a process control system. The I/O module 15 comprises a channel communications interface 15a which enables the I/O channel of the I/O module to communicate with a field device. In particular, the channel communications interface 15a is configured to be connected to an I/O module cable 17, to thereby connect the I/O module 15 to the field device 13.
The I/O module 15 is able to physically connect with the cable interface 9 of the mobile I/O module communications device 1 by physically connecting the cable interface 9 of the mobile I/O module communications device 1 to the I/O module cable 17 connected to the I/O module 15. The I/O module cable 17 is connected to both the field device 13 and the I/O module 15 during operation. The I/O module cable 17 may or may not be connected to the field device 13 when utilising the mobile I/O module communications device 1. The mobile I/O module communications device 1 may thereby send the field device ID to the I/O module 15, and in particular to the I/O channel connected to the field device 13.
The I/O module 15 may also include a storage unit 15b which contains an I/O channel ID of the I/O channel, or of each I/O channel in case the I/O module 15 has more than one I/O channel. The storage unit 15b may according to one variation be arranged to store a field device ID sent from the mobile I/O module communications device 1 to the I/O module 15. The I/O module 15 is configured to send the received field device ID to the engineering tool ET and/or to the controller 19. The I/O module 15 may also be configured to send the I/O channel ID together with the field device ID, and/or at least one of the I/O module ID and the I/O cabinet ID. According to the example, field device 13 is provided with a field device ID tag 13b. The field device ID tag 13b may be physically arranged on the field device 13. As previously mentioned, the field device ID tag may for example be an image showing the field device ID, an RFID tag, a bar code, a QR code or similar. The mobile I/O module communications device 1 obtains the field device ID contained in the field device ID tag. The field device tag could alternatively be provided in a physical list, on a blueprint of the plant, including the position of all field devices, or a digital list for example stored in the mobile I/O communications device.
As described above, the mobile I/O module communications device 1 may for example be configured to obtain the field device ID by itself, reading the field device ID tag 13b or it may be obtained from a mobile ID tag reading device 21, both examples being illustrated in Fig. 2.
The mobile ID tag reading device 21 may for example be a smart phone or a tablet computer provided with a field device ID tag reading application. The mobile ID tag reading device 21 may be configured to send the field device ID wirelessly, or via a wired connection, for example by attaching an adapter to the mobile ID tag reading device 21, which adapter enables the set up of a wired connection between the mobile ID tag reading device 21 and the mobile I/O module communications device 1. When the field device ID has been obtained by the mobile I/O module communications device 1, the mobile I/O module communications device 1 may send the field device ID to the I/O module 15. The mobile I/O module communications device 1 may in particular send the field device ID after the mobile I/O module communications device 1 has been physically connected to the I/O module cable 17.
According to one variation, the mobile ID tag reading device 21 may send a command to the mobile I/O module communications device 1 that the mobile I/O module communications device 1 shall send the field device ID to the I/O module 15. To this end, the mobile ID tag reading device may include a user interface, which enables a user to determine when to send the command to the mobile I/O module communications device 1.
The I/O module 15 may according to one variation be configured to send an acknowledgement, which contains the I/O channel ID and the I/O module address, i.e. the I/O module slot number of the I/O cabinet, back to the mobile I/O module communications device 1. The mobile I/O module communications device 1 may then be configured to send this information to the engineering tool ET for setting up the connection between the field device and the I/O module in question.
Fig. 3 shows an example of a process control system 23 comprising a controller 19 and a first I/O cabinet 16a comprising a plurality of I/O modules 15-1 to 15-3 installed therein, and field devices 13-1 to 13-3, each field device 13-1 to 13-3 being physically connected to a respective I/O module 15-1 to 15-3 by means of I/O module cables. According to the example, each field device 13-1 to 13-3 is provided with a respective physical field device ID tag 25-1 to 25-3.
The process control system 23 furthermore comprises a second I/O cabinet 16b comprising a plurality of I/O modules 15-4 to 15-6 installed therein, and field devices 13-4 to 13-6, each field device 13-4 to 13-6 being connected to a respective I/O module 15-4 to 15-6 by means of I/O module cables. According to the example, each field device 13-4 to 13-6 is provided with a respective physical field device ID tag 25-4 to 25-6.
In the example, the field devices 13-1 to 13-6 are assumed to be non-smart field devices or binary devices.
The process control system 23 also comprises an engineering tool ET. The entire process control system 23 is communicatively connected via a communications network N.
In an example situation in which the process control system 23 is configured, for example during commissioning, a user carries the mobile I/O module communications device 1 in the process control environment. The user may optionally also carry a mobile ID tag reading device 21. According to the example in Fig. 3, the user approaches field device 13-1 and reads the field device ID tag provided on the field device 13-1. At this point, the field device ID contained therein is thereby obtained, either by the mobile I/O module communications device 1 or by the mobile ID tag reading device 21. In the latter case, the mobile ID tag reading device 21 sends the field device ID to the mobile I/O module communications device 1.
The user physically connects the cable interface 9 of the mobile I/O module communications device 1 to I/O module cable 17-1. When doing so, normally the I/O module cable 17-1 will not have to be disconnected from field device 13-1. Instead, the cable interface 9 may be arranged e.g. around the I/O module cable 17-1 to thereby obtain an electromagnetic coupling, or an electrical coupling.
When the mobile I/O module communications device 1 has obtained the field device ID, the field device ID may be sent to I/O module 15-1 via the I/O module cable 17-1. The storage unit 15a of the I/O module 15-1 can thus store the field device ID and/or it may send it to the engineering tool ET or to the controller 19. Concurrently with sending the field device ID, the I/O module 15-1 also sends at least one of the I/O channel ID of the I/O channel that received the field device ID, the I/O module ID of the receiving I/O module 15-1 and the I/O cabinet ID of the receiving I/O cabinet 16a.
In this manner a connection between field device 15-1 and the I/O module 15- 1 to which field device 13-1 is connected to, may be established at the engineering tool level or at the controller level. This may for example be utilised when adapting the control program code in accordance with the topology of the process control system 23.
When this procedure has been carried out, the user disconnects the cable interface 9 from the I/O module cable 17-1 and repeats the procedure with the remaining field devices 13-2 to 13-6 and corresponding I/O modules 15-2 to 15-6. In this manner the connections between all I/O modules and all field devices, including non-smart and binary field devices, can be obtained.
Should however some of the field devices be smart field devices programmed with a field device ID tag, this procedure would not have to be carried out with those field devices. It should be noted that this procedure may be performed also in case one or more I/O module has a plurality of I/O channels; each I/O channel is also in this case connected to a unique field device, and each I/O channel has a unique I/O channel ID. The process may be carried out before or after the I/O module is connected to the rest of the process control system.
As briefly mentioned above, it is also envisaged that instead of obtaining the field device ID from a physical tag provided on a field device, the field device ID tag could be selected from a list of field devices each having a unique field device ID tag. To this end, the mobile I/O module communications device could be provided with a user interface, and contain the list of field devices included in the plant installation such that a user could select a field device in the list whereby the processing circuitry would obtain the field device ID to be sent to an I/O module. Alternatively, the mobile ID tag reading device could be provided with the list, from which a user could select field device ID tags and send them to the mobile I/O module communications device.
According to yet another variation, the field device ID tag may be provided on plant blueprint or in a list on a piece of paper carried by the user. The field device ID tag could then be fed e.g. manually into the mobile I/O module communications device via a user interface or via the mobile ID tag reading device.
The inventive concept has mainly been described above with reference to a few examples. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the inventive concept, as defined by the appended claims.

Claims

1. A mobile I/O module communications device (1) for setting up cable connections between field devices (13) and I/O modules (15) in a process control system (23), wherein the mobile I/O module communications device (1) comprises: a cable interface (9) configured to physically connect to an I/O module cable (17) that connects an I/O module (15) with a field device (13), and processing circuitry (3) configured to obtain a field device ID uniquely identifying a field device (13) distinct from the mobile I/O module
communications device (1), wherein the processing circuitry (3) is configured to send the field device ID to an I/O channel of an I/O module (15) via an I/O module cable (17) connected to the cable interface (9) and to the I/O module (15).
2. The mobile I/O module communications device (1) as claimed in claim 1, comprising a communications unit (5) configured to receive the field device
ID from an external mobile ID tag reading device (21).
3. The mobile I/O module communications device (1) as claimed in claim 1, comprising an ID tag reader arranged to read a field device ID tag (13a) physically arranged on a field device (13), and wherein the processing circuitry is arranged to obtain the field device ID from the field device ID tag (13a).
4. The mobile I/O module communications device (1) as claimed in any of the preceding claims, wherein the cable interface (9) comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device (1) physically to the I/O module cable (17) to thereby enable the cable interface (9) to send the field device ID via the cable to an I/O channel of an I/O module (15) connected to the I/O module cable (17).
5. The mobile I/O module communications device (1) as claimed in any of the preceding claims, comprising modulation circuitry (7) configured to feed the cable interface (9) with a signal that includes the field device ID, which enables the cable interface (9) to send the field device ID to an I/O module (15) connected to the cable interface (9) by means of an I/O module cable (17).
6. A system (11) for setting up cable connections between field devices (13) and I/O modules (15) in a process control system (23), wherein the system (11) comprises: - a mobile I/O module communications device (1) comprising: a cable interface (17) configured to physically connect to an I/O module cable (17) that connects an I/O module (15) with a field device (13), and processing circuitry (3) configured to obtain a field device ID uniquely identifying a field device (13) distinct from the mobile I/O module communications device (1);
- an I/O module (15) having an I/O channel, wherein the I/O
module (15) comprises: a channel communications interface (15a) enabling the I/O channel to communicate with a field device (13), which channel communications interface (15a) is physically connectable to the cable interface (9) of the mobile I/O module communications device (1) by means of an I/O module cable (17), wherein the processing circuitry (3) is configured to send the field device ID to the I/O channel of the I/O module (15) via an I/O module cable (17) connected to the cable interface (9) and to the I/O module (15), and l8 wherein the channel communications interface (15a) is configured to receive the field device ID from the mobile I/O module communications device (1).
7. The system (11) as claimed in claim 6, wherein the I/O module (15) comprises a storage unit (15b), wherein the I/O module (15) is configured to store the field device ID in the storage unit (15b), thereby providing a link between an I/O channel ID of the I/O channel and the field device ID.
8. The system (11) as claimed in claim 6 or 7, wherein the channel communications interface (15a) is configured to send the field device ID tag and at least one of a corresponding I/O channel ID of the I/O channel, I/O module ID and I/O cabinet ID to one of an engineering tool (ET) and a controller (19).
9. The system (11) as claimed in any of claims 6-8, wherein the mobile I/O module communications device (1) comprises modulation circuitry (7) configured to feed the cable interface (9) with a signal that includes the field device ID, which enables the cable interface (9) to send the field device ID to an I/O module (15) connected to the cable interface (9) by means of an I/O module cable (17).
10. The system (11) as claimed in any of claims 6-9, comprising a mobile ID tag reading device (21) configured to read field device ID tags provided physically on field devices (15), and to send field device ID extracted from a field device ID tag to the mobile I/O module communications device (1).
11. The system (11) as claimed in claim 10, wherein the mobile ID tag reading device (21) is configured to send a command to the mobile I/O module communications device (1) to send the received field device ID to an I/O module (15) via the cable interface (9).
12. The system (11) as claimed in claim 10 or 11, wherein the mobile I/O module communications device comprises a communications unit (5) configured to receive the field device ID from the mobile ID tag reading device (21).
13. The system (11) as claimed in any of claims claim 6-9, wherein the mobile I/O module communications device comprises an ID tag reader arranged to read a field device ID tag physically arranged on a field device (15), wherein the processing circuitry (3) is configured to extract the field device ID from the field device ID tag.
14. The system (11) as claimed in any of claims 6-13, wherein the cable interface (9) comprises a cable attachment member arranged to temporarily connect the mobile I/O module communications device physically to an I/O module cable (17) to thereby enable the cable interface (9) to send the field device ID via the I/O module cable (17) to an I/O channel of an I/O module (15) connected to the I/O module cable.
PCT/EP2015/075086 2015-10-29 2015-10-29 A mobile i/o module communications device and a system for process control system cable configuration WO2017071755A1 (en)

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