US20050018643A1

US20050018643A1 - Industrial wireless network

Info

Publication number: US20050018643A1
Application number: US10/856,349
Authority: US
Inventors: Paul Neilson; John Sanford; Justin Schumacher
Original assignee: Adaptive Instruments Corp
Current assignee: Adaptive Instruments Corp
Priority date: 2003-05-30
Filing date: 2004-05-28
Publication date: 2005-01-27
Also published as: WO2004109984A2; US8971938B2; WO2004109984A3; US7672683B2; US20050036478A1; US20100120457A1; US20080153528A1; US20040242249A1

Abstract

A system for wirelessly communicating between multiple devices of a process control system is disclosed. The system includes a basestation that communicates with multiple field units via a wireless signal and in accordance with a wireless protocol. The wireless protocol is made up of frames that are defined by multiple time slots, an initial one of which is reserved for a wireless start-frame message from the basestation to multiple field units. The base station utilizes the start-frame message to assign the remaining time slots to field units and to provide information to synchronizing the field units to the basestation.

Description

BACKGROUND OF THE INVENTION

This application is a continuation-in-part of copending, commonly assigned U.S. patent application Ser. No. 10/449,455, filed May 30, 2003, entitled “Non-Interfering Multipath Communications Systems,” the teachings of which are incorporated herein by reference. This application is related to copending, commonly assigned U.S. patent application Ser. No. ______, (Express Mail Label No. EV 324 849 470 US) entitled “Industrial Wireless Network With Message Authentication,” filed this same day herewith, the teachings of which are incorporated herein by reference. The present invention relates to methods and apparatus for wireless communications, and in particular to, systems for wireless communications among multiple devices for process control, e.g., for monitoring and controlling manufacturing, industrial, environmental, and other processes.
Modern manufacturing techniques often rely on automated monitoring and control systems to assure safe and efficient operation. Such systems use remote sensors and actuators to measure and set equipment states points throughout a process. For example, remote sensors can be positioned to collect temperature and pressure data and to send that information to a controller that monitors the overall process. Furthermore, the controller can send commands to valves and other actuators to adjust system parameters and, thereby, assure optimal system performance.
Electronic monitoring and control via remote sensors and actuators has proven an effective tool in automating and managing processes, even processes spread over large physical areas. Unfortunately, conventional control systems are expensive to set-up and maintain. The expense of wiring communication and electrical lines between remote monitoring units and central controllers can offset many of the systems' advantages. In addition, the harsh environment found in manufacturing plants, combined with circuitous runs of wires along inaccessible routes, can make maintenance difficult.
In addition, such systems are difficult and expensive to change once in place. As a result, there is a disincentive to improving the process and upgrading the sensors, actuators, and other control equipment. Control systems are thus rendered obsolete, costing millions in lost opportunity.
Therefore, a need exists for a flexible, low cost, methods and apparatus for process control applicable in manufacturing, industrial, environmental, and other process control systems.

SUMMARY OF THE INVENTION

The present invention provides apparatus and methods for wireless communication between multiple devices of a process control system. In one aspect, a system includes a basestation that communicates with multiple field units via a wireless signal and in accordance with a wireless protocol. The wireless protocol is made up of frames that are defined by multiple time slots, an initial one of which is reserved for a wireless start-frame message from the basestation to multiple field units. The base station utilizes the start-frame message to assign the remaining time slots to field units and to provide information to synchronizing the field units to the basestation.
In another aspect of the invention, the basestation utilizes the initial time slot for a start-frame message which alerts the field units that one or more of the remaining time slots within the frame are available for logon requests from the field units. At least one of the field units can wirelessly respond to the basestation and send a logon request in one of the available time slots. In a related aspect of the invention, at least one additional time slot is reserved for a response from the basestation to any field unit that requests to log on.
In yet another aspect of the invention, the basestation sends a start-frame wireless message which directs multiple field units to send data in assigned time slots. In one embodiment, the start-frame wireless message overrides a selection of data normally sent by a field unit.
Preferably, the basestation sends a wireless start-frame message that includes a header portion, a data portion, and an error detection and correction portion. In addition, the start-frame message preferably contains information about the number of frames and the frame number. In another embodiment, the start-frame message also includes information on the frequency of the wireless signal. The aforementioned and other aspects of the invention are evident in the drawings and in the text that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an illustration of one embodiment of the system of the present invention;
FIG. 2 is an illustration of synchronous frame in the wireless protocol of the present invention;
FIG. 3 is an illustration of an asynchronous frame of the wireless protocol of the present invention;
FIG. 4 is another embodiment of the synchronous frame of the present invention;
FIG. 5 is another embodiment of the asynchronous frame of the present invention;
FIG. 6 is yet another embodiment of the asynchronous frame of the present invention;
FIG. 7 illustrates an additional embodiment of the asynchronous frame of the present invention;
FIG. 8 illustrates a multiframe in the wireless protocol of the present invention;
FIG. 9 is another embodiment of the multiframe of the present invention;
FIG. 10 illustrates a superframe in the wireless protocol of the present invention;
FIG. 11 is a chart of preferred frame lengths and frame durations for various baud rates in the wireless protocol of the present invention;
FIG. 12 is a chart of maximum frame transmit duty cycle for various baud rates;
FIG. 13 is a chart of the maximum synchronous times slots during a ten second period in one embodiment of the wireless protocol of the present invention;
FIG. 14 illustrates an exemplary code generator for use with the wireless protocol of the present invention;
FIG. 15 illustrates the structure of a message in one embodiment of the wireless protocol of the present invention;
FIG. 16 illustrates the header block of the message in FIG. 15;
FIG. 17 illustrates a preferred data byte alignment of the message in FIG. 15;
FIG. 18 illustrates a start-frame message of the wireless protocol of the present invention;
FIG. 19 illustrates the header block of the start-frame message in FIG. 18;
FIG. 20 illustrates a synchronous embodiment of the data block of the start-frame message in FIG. 18;
FIG. 21 illustrates an asynchronous embodiment of the data block of the start-frame message in FIG. 18;
FIG. 22 illustrates the error detection and correction block of the start-frame message in FIG. 18;
FIG. 23 illustrates a synchronous frame field unit data message of the wireless protocol of the present invention;
FIG. 24 illustrates the header block of the synchronous frame field unit data message in FIG. 23;
FIG. 25 illustrates the data block of the synchronous frame field unit data message in FIG. 23;
FIG. 26 illustrates the packing of the data block in FIG. 25;
FIG. 27 illustrates the error detection and correction block of the synchronous frame field unit data message in FIG. 23;
FIG. 28 illustrates an asynchronous frame basestation data message of the wireless protocol of the present invention;
FIG. 29 illustrates the header block of the asynchronous frame basestation data message shown in FIG. 28;
FIG. 30 illustrates the data block of the asynchronous frame basestation data message shown in FIG.28;
FIG. 31 illustrates the packing of the data block in FIG. 30;
FIG. 32 illustrates the error block of the asynchronous frame basestation data message shown in FIG. 28;
FIG. 33 illustrates an asynchronous frame field unit data message of the wireless protocol of the present invention;
FIG. 34 illustrates a message stream of the wireless protocol of the present invention using redundant basestations;
FIG. 35 illustrates a message stream of the wireless protocol of the present invention one basestation;
FIG. 36 illustrates the message stream of FIG. 35 after a new basestation logs on to the wireless network;
FIG. 37 illustrates a message stream of the wireless protocol of the present invention after one of the multiple basestations becomes inoperable; and
FIG. 38 illustrates a schematic of multiple basestations connected with a data collection.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes various embodiments of process control methods and apparatus. In one embodiment, a system includes a basestation that communicates with multiple field units via a wireless signal and in accordance with a wireless protocol. FIG. 1 illustrates the application of such a system to a manufacturing process, including a basestation 10 and multiple field units 12. The field units 12 are positioned at points within the process for wirelessly monitoring and/or controlling the system at the direction of basestation 10. For example, the field units can control valves 14, pumps 16, and/or other process equipment. In addition, field units can monitor temperature, pressure, flow rate, fill levels, and other process variables at positions, such as in fluid conduits 18 and/or tanks 20.
Basestation 10 comprises a convention controller of the type known in the art, e.g., including a processor, memory, storage, and input/output control sections. The basestation can be embodied in an embedded system, personal computer, workstation, mainframe, or the like, as known in the art. And, it can be coupled to a user interface and/or communications interface (e.g., for networking) to provide information about system parameters and/or receive inputs for system control. Basestation 10 also includes a transceiver 24 capable of sending and receiving wireless signals in accordance with the wireless protocol discussed in detail below. The illustrated transceiver operates at 900 Mhz, although it can operate at other rates as well, e.g., 2.4 to 5.6 Ghz, and can exercise the protocol detailed below on top of industry standards and/or proprietary low-level protocols.
Field unit 12 comprises a sensor and/or actuator of the type commonly known in the art, as well as, logic for executing commands received from the basestation for monitoring and controlling a process, all in the conventional manner known in the art. The field unit 12 can be a so call “smart field device” of the type commercially available in the art, or it can be a conventional field device equipped with a conventional interface for use in process control. The field unit includes a processor for performing the various task described below, such as, for example receiving, storing, processing, creating, and/or sending messages in accordance with the wireless protocol; collecting, processing; storing, and/or receiving system data; and/or controlling system actuators. The field units preferably also include a wireless transceiver for communicating with the basestation or other field units.
One skilled in the art will appreciate that, while the basestation illustrated in FIG. 1 is a controller and the field units are field devices, those roles could be reversed. Thus, for example, one of the field devices (presumably a smart field device) could serve as the basestation and the controller could serve as a field unit. Moreover, it will be appreciated that other equipment, regardless of whether it is a controller or field device, could serve as a field unit.
Unlike conventional systems that require long runs of wire between remote units and a central unit, the present invention provides a wireless network of field units and a basestation for monitoring and/or controlling a process. The wireless protocol provides reliable data transfer having update rates capable of keeping pace with the changing process control and monitoring demands of an intricate manufacturing system. The result is a flexible, robust system which provides optimized process control without the expense and maintenance problems associated with wires.
The basestation and field units communicate via a wireless protocol comprising frames that define organized segments of communication. Frames can vary in bit length, but are preferably always the same length. In one embodiment, every frame is 1704 bits in total length. The frames are divided into time slots in which field units or the basestation can send or receive a message. Preferably, every frame is divided into eight time slots.
In one aspect of the invention, the basestation and field units communicate with synchronous and asynchronous frames. Synchronous frames are primarily designed for transmitting measurement data to the basestation and include a start frame message from the basestation that assigns the remaining time slots to specific field units. Asynchronous frames are designed for moving large amounts of data between the basestation and a field unit(s). Unlike synchronous frames, asynchronous frame can include unassigned time slots or time slots assigned generally to a group (i.e., the field units). For example, a field unit can use an unassigned time slots in an asynchronous frame to log onto the wireless network.
Although the following description includes specific bit lengths, one skilled in the art will appreciate that these numbers are exemplary and the bit lengths can be varied to suit the demands of the system.
Both synchronous and asynchronous frames start with the basestation transmitting a start-frame message in the first time slot. FIGS. 2 and 3 illustrate an exemplary synchronous frame 30 and asynchronous frame 32, respectively, of 1704 bits with a first time slot assigned to the basestation and used for a start-frame message.
In synchronous frames, the start frame message from the basestation allocates the remaining seven time slots of the respective frame to the field units. Conversely, allocation of the seven remaining time slots in an asynchronous frame is variable, with one to six time slots available for the basestation and one to five time slots available to the field units. The basestation assigns the time slots to the field units in the asynchronous frame depending on how many timeslots have been used by the basestation and the type of data being transmitted.
In synchronous frames, messages sent by the field units and the basestation preferably fit within the time slot to which they are assigned. When a field unit needs to transmit more data than can be contained within a single message, the basestation assigns the field unit multiple time slots for multiple messages. In some cases, these time slots are in adjacent frames. For example, FIG. 4 illustrates one field unit assigned to time slots seven and eight of a first synchronous frame and to time slot two in the next synchronous frame. In asynchronous frames, the length of messages are not designed to match the length of a single time slot and instead vary depending on how much data is being transmitted and the available space within the frame.
FIGS. 5 and 6 illustrate asynchronous frames containing messages of varying size. In FIG. 5, the basestation uses the first time slot for the start frame message plus an additional time slot to request data, while the field unit employs time slots four and five to send the requested data. In FIG. 6, the field unit uses the bulk of the frame to send a message to the basestation and the basestation uses only the first time slot for the start frame message and time slot seven to reply to the field unit's message. Time slot eight is reserved for quiet time.
The basestation preferably reserves the last time slot in every asynchronous message for quiet time so that the basestation can switch modes and prepare data for the next message frame. Quiet time is preferably also included after any message from the basestation. For example, 104 bits of quiet time are reserved at the end of any basestation message, such as, for example at the end of a start frame message. Quiet time allows the basestation and field units to perform functions such as switching from transmit to receive mode and changing configuration registers. Similarly, quiet time at the end of other basestation messages provides time for the basestation radio frequency transceiver to switch from transmit to receive mode and for the field units to process received data and prepare an ACK/NAK response message. The end of field unit messages preferably also includes quiet time. For example, forty bits of quiet time can be reserved between field unit messages (FIG. 2).
As stated above, field units use asynchronous frames to log into the radio frequency network. Since the basestation and field units use asynchronous frames for multiple purposes, not every asynchronous frame will be available for a login request and field units check the start-frame message to verify that the asynchronous frame is available for login requests.
Asynchronous frames available for a login request preferably have three time slots reserved for field units to send a login request and two time slots reserved for the basestation to respond to all login requests. The remaining two slots are left as quiet time to allow the basestation/field units time to process the data with the frame and to switch from transmit to receive mode. Since the basestation does not know when a field unit may attempt to log into the network, the three field-unit-login time slots in each login frame are used on a first come basis and collisions may occur. To minimize the possibilities of conflicts, field units randomly pick one of the three time slots, as well as, the asynchronous frame in which to send the login request message.
FIG. 7 illustrates an exemplary asynchronous message with time slots available for login requests by the field units. If the basestation accepts the field unit's login request, the basestation will preferably respond by transmitting information to the field unit concerning the configuration of the network, such as, for example the unit's radio frequency identification number and the location of a future time slot reserved for the device.
The frames of the present invention are preferably grouped into multiframes having between about two and sixty-three frames and including at least one asynchronous and one synchronous frame. The basestation conveys the number of asynchronous and synchronous frames per multiframe to a field unit when it logs into a network along with additional information relating to the network configuration. FIG. 8 shows an exemplary multiframe.
The at least one asynchronous frame in the multiframe provides an opportunity for tasks such as logging on and/or sending/retrieving configuration information from a device. Since the number of frames in a multiframe is configurable, the cycle can be shortened for smaller networks to increase the field unit update rate and minimize the time required to send/receive asynchronous data messages. FIG. 9 illustrates a shortened multiframe cycle.
The wireless protocol also includes superframes which contain a group of multiframes and define the total number of time slots available in a network. The size of a superframe is preferably between about one and sixty-three multiframes. FIG. 10 illustrates the organization of an exemplary superframe. The superframe size and the number of synchronous frames per multiframe determine the total number of synchronous time slots in a network. This number can be calculated base on the number of synchronous frames, the number of available time slots in a synchronous frame, and the superframe size.
The wireless protocol can operate at a number of different data baud rates depending upon the application's requirements. Installations with a large number of devices in a small coverage area can preferably be run at a higher data rate while a network containing devices installed in a large area, especially if the area contains obstructions, can be run at lower data rate to maximize the radio frequency sensitivity.
Regardless of the baud rate, the wireless protocol allows the key timing requirements to remain the same and the transmit duty cycle to remain under 10 percent. FIG. 11 illustrates the preferred frame length and time slot duration at various baud rates and FIG. 12 shows the resulting maximum frame transmit duty cycle per device for the various baud rates. As described herein, the wireless protocol is optimized for 76800 baud. Although, the protocol works at other baud rates, it will be slightly less efficient due to the fixed number of time slots per frame and the unnecessarily long inter-time slot quiet times. FIG. 13 shows a chart of the maximum synchronous time slots in a 10 second period for different baud rates assuming there are forty-nine synchronous frames for a multiframe consisting of fifty frames in total length.
One of the advantages of the wireless protocol is the ability to use transmissions in the 900 MHz spectrum. Since this spectrum is designated for open use, setting up the wireless network will not require special licensing.
Preferably, the basestation and field units transmit wireless messages at a frequency in the range of about 902 MHz to 928 MHz. In yet another embodiment, the transmitting frequency changes after each frame. By changing frequencies or “hopping” between frequencies, the chance of noise creating an interfering signal is reduced. In addition, hopping frequencies adds a measure of security because outside systems do not know which channel will be selected for the next frame.
Frequency hops preferably occur at the end of a message frame after all data from the field units and/or basestation has been transmitted. A 16-stage Gold code sequence pseudo noise generator preferably generates the hopping sequence using the lower 16-bits of a unique 32-bit number (MAC address) assigned to the base station as the seed for the lower linear feed-back shift registers used in the code generator. As an additional advantage, Gold code generators produce an equal number of 1's and 0's, and will output each possible code only once before the sequence repeats. FIG. 14 shows an exemplary Gold code generator for use in the network of the present invention. A person skilled in the art will appreciate that other generators can generate the hopping sequence, and particularly those generators capable of producing a large number of different sequences, each with a low correlation to the other codes.
To minimize processing on the battery power field units, the basestation and/or field units will preferably generate the hopping sequences once and store them in a table instead of being calculated on the fly. Pre-generated tables and a sequence clock transmitted with basestation messages can also minimize the time required for field units to synchronize with the basestation hopping sequence.
All messages in the wireless protocol preferably have the same structure, including a header block, a data block, and an error detection and correction block. FIG. 15 illustrates the structure of an exemplary message. The header block of a wireless message preferably includes a synchronization preamble, a MAC Address, and possible additional bits as shown in FIG. 16. The first 32 bits of a header block preferably consist of an initial alternating 10101010 . . . preamble used by the receiving device to synchronize with a transmitted radio frequency data stream. The next 32 bits of the header block are preferably occupied by the MAC address field, which is used in the pattern match registers of the receiving radio frequency transceivers. The MAC address can include 4 transition bits, one bit to indicate the type of message being sent, and a 27-bit unique number assigned every radio frequency device used with the network. A message type bit of 1 indicates a frame start or a synchronous frame data message and a message type bit of 0 indicates an in-frame asynchronous data message.
The data block portion of a message preferably contains the actual payload of a packet, with the size of the data block varying based on the type of frame and the information contained therein. All data is preferably sent out with the most significant bit first. An exemplary byte alignment is shown in FIG. 17, including at least one 0 to 1 or 1 to 0 bit transition for every eight bits transmitted and the use of 8 bit groups.
The final block in the message, the error detection and correction block, preferably contains a number of bits used to determine if the message has any errors, as well as, to correct a limited number of bit errors.
Start-frame messages, like all other messages, preferably contain three blocks as shown in FIG. 18. The first block, the header block, is illustrated in FIG. 19, and preferably includes the 32 bit alternating 10101 . . . preamble, followed by the basestation's 32 bit MAC address. The message type is set to a value of 1 to distinguish the message as a start-frame message. The header also holds the hopping sequence clock, which the listening devices use to synchronize with the network's frequency hopping sequence, and information on the current multiframe number, the current frame number and type, and the total frames per multiframe.
The structure of the data block in a start frame message depends on whether the frame is synchronous (FIG. 20) or asynchronous (FIG. 21). In synchronous start-frame messages, the data block consists of 3 fields, each of can contain information for a basestation or field unit that may have been allocated a time slot within the frame. All fields in the data block are preferably bit field variables with the most significant data bit holding data from the field unit that has been allocated time slot two and the least significant data bit for holding data for the field unit with time slot eight. The basestation uses the first field, the Asynchronous COM Request Field (FIG. 20), to indicate to one or more field units that there is data waiting to be transferred to the field unit in one or more of the future asynchronous message frames. A bit value of 1 indicates that the field unit should start listening to all asynchronous message frames for possible data. The basestation uses the second field, the Time Slot Acknowledge Field, to ACK/NAK a message sent previously in the same synchronous multiframe/frame. If the message received by the basestation contained errors or was never received, the bit value will be 0. If the basestation successfully received the message, the bit value will be 1. The basestation can use the third field, the Requested Measurement/Information Channel Field, to override the selection of data normally set by a field unit in a time slot and to request specific measurement data.
In asynchronous start-frame messages, the data block in the start frame message contains different information. As shown in FIG. 21, the first field in the data block contains the radio frequency identification of the field unit for which the asynchronous frame is reserved. The basestation sets this value to 0 if the frame is not reserved and any field unit may attempt to send a login request message. The other field in the data block contains the length of the asynchronous data block sent from the basestation to the field unit. If the basestation sends no data in the remainder of the frame's time slots, the basestation sets this value to 0.
The final portion of the basestation's start-frame messages includes an error detection and correction block. FIG. 22 illustrates an exemplary error block having a 16-bit CRC and eight error correction bits. A Hamming code can provide a basic level of error correction with only a small overhead of a few added bits and a short processing time to encode/decode the message. The error detection and correction block protects all bits in the message frame except for the synchronized preamble and MAC address fields in the header block.
In response to a basestation's synchronous start-frame message, a field unit preferably replies with a synchronous frame data message. With reference to FIGS. 23 through 27, an exemplary synchronous frame data message includes a header block, a data block, and an error detection and correction block. The header block, shown in FIG. 24, starts with the usual 32 bits of alternating 1010 . . . for a preamble, followed by the field unit's MAC address. The field unit sets the message type bit to a value of 1 to distinguish this message as a synchronous data type. The data block, shown in FIG. 25, contains seven bytes of data with an additional byte's worth of transition bits. To optimize the packing of the field unit's information, the field unit produces synchronous messages having data bytes packed in groups of 8 bytes with the most significant bit of each of the seven data bytes being stripped off and stored in the lower seven bits of the last byte. The field unit then inserts a transition bit in the most significant bit of the all the eight bytes. The preferred data packing structure is illustrated in FIG. 26.
The field unit can assign data bytes to deliver specific information. For example in one assignment scheme, the first byte delivers the status of the field unit (8 bit flags); the second through fifth byte deliver the value for the measurement/information channel being delivered (this may be anything from a floating point value to 4 individual bytes and is defined by the valued of later bytes); the sixth byte delivers the field unit type; and the seventh byte delivers measurement/information channel information.
Finally, as shown in FIG. 27, the field unit data message can include an error detection and correction block identical to the error block used in the basestation start-frame message.
During asynchronous frame, the basestation can send two different types of messages, an asynchronous start-frame message and an asynchronous data message. An exemplary asynchronous data message is illustrated in FIG. 28 and includes a header block, a data block of variable size, and an error detection and correction block.
An asynchronous data message from a basestation starts with a short header block (FIG. 29), including a 32 bit preamble, a 32-bit MAC address, a command/data type field, and a data block length field. Unlike other basestation messages, the message type bit in the MAC address field will be set to 0 to distinguish this message as an in-frame asynchronous data message. Since this field is used to set the value of the pattern match registers on radio frequency transceivers, changing this bit will avoid the problem of field units accidentally receiving this message when attempting to synchronize with the basestation start-frame message stream.
The data block in the basestation asynchronous data message can vary between about 14 and 848 bits. Due to the requirement by the radio frequency transceivers for transition bits, the actual data that can be contained in this block is about 1 to 91 bytes. FIG. 30 illustrates an exemplary data block. To optimize the packing of the basestation's data, the basestation packs the data bytes in groups with the most significant bit of each data byte stripped off and stored in the lower seven bits of the last byte in the group. If the message consists of less than seven data bytes or of a number of bytes not a multiple of seven, the last byte in the group will hold the most significant bits of the previous bytes. FIG. 31 illustrates basestation data packing.
The final portion of a basestation asynchronous data message contains an error correction and detection block as shown in FIG. 32. This block is similar to the error detection blocks used elsewhere in other messages and preferably includes a 16-bit CRC, as well as, Hamming code error correction bits. In one aspect, the basestation asynchronous data message error detection block preferably includes twelve error correction bits, instead of the normal 8 bits, to handle the additional length of some asynchronous data messages.
Field units can also send asynchronous data messages, which are identical to the basestation asynchronous data messages except for the substitution of the field unit's MAC address in the header block. FIG. 33 illustrates a field unit asynchronous data message.
In one embodiment, the basestation and field units encrypt the messages transmitted in the wireless protocol. For example, the system can include a 48-bit weak encryption scheme to encrypt all messages sent by either a basestation or a field unit.
The simplified set-up of the wireless network reduces user errors and speeds instillation. A user only needs to input the radio frequency baud rate, the MAC address of the primary basestation on the network, the MAC address of the all field units on the network, and/or an encryption key into the various network devices. Set-up preferably begins with a site survey to determine a good physical location for the basestation. A user then mounts the basestation, and selects the baud rate through either a keypad attached to the basestation or a PC configuration tool communicating with the basestation over a secure wired interface (i.e., RS485 serial or Ethernet cable). MAC addresses of all the field units are also preferably entered into the basestation.
After the basestation has been installed and is operating, the user can configure the field units with the baud rate, the primary basestation's MAC address, and the network encryption key (if used). All values are preferably entered into the field unit using a wired connection. After configuration, the field units can then log into the network. When the field unit's login request is accepted by the basestation, the basestation will preferably send the field unit any other needed information. For example, the basestation can send the field unit the radio frequency identification, the value of various network parameters (e.g., the number of asynchronous frames per multiframe), and the location of a future synchronous time slots that has been reserved for the device.
A number of different elements, taken together, provide security for the network and result in secure data transmission. For example, frequency hopping provides a basic level of privacy because the shear number of different hopping sequences makes it unlikely that neighboring networks would have the same hopping sequence or could easily decipher the pattern.
The use of unique identifiers associated the basestation and field units further protect the system by providing a method for authenticating messages. For example, each message sent by a network device can contain a unique identifier which the receiving device uses to confirm the authenticity or origin of the received message. In one embodiment, the identifier is a MAC address. The receiving device can check the MAC address against a stored list of MAC addresses associated with the devices on the network. If the received MAC address does not match a MAC address on the list, the receiving device preferably does not accept the message. In addition, where a device is assigned to a specific time slot, any message received during that time slot can be checked against the stored MAC address for the device assigned to that time slot. If the MAC address does not match, the receiving device preferably rejects the message.
The basestation and field units can also use the basic timing of the messaging protocol to authenticate the messages. In one embodiment, the network devices check the time at which the identifier is received to authenticate a message. In another embodiment, the network devices use the frequency at which the MAC address is received to authenticate a message. In addition, the timing and frequency of the message as a whole can be used in the authentication process. The basestation or the field units can then reject any message not sent at the correct time or at the correct frequency. As an additional authentication measure, devices on the network can range check data to determine if the data falls within a valid range. If data falls outside the measurable range of a sensor or is not a physically possible result, the receiving device does not accept the message and/or the data contained therein.
As an additional authentication measure, devices on the network can range check data to determine if the data falls within a valid range. If data falls outside the measurable range of a sensor or is not a physically possible result, the receiving device does not accept the message and/or the data contained therein.
Authenticating messages and/or data protects the system from passing on random or garbage information. For example, if signal interference garbles transmitted data, the authentication scheme minimizes the chance of passing on invalid data. Instead, the sending device will note the error and the data can be resent. Alternatively, or in addition, the basestation can generate an error message for the system's user.
Redundant basestations can further improve network reliability. For example, multiple basestations operating on the same hopping frequency provide multiple paths for data receipt. In one embodiment, basestations can take turns on a round-robin basis with the job of network master passing between different basestations. The master basestation can transmit the start frame message for an entire superframe to synchronize the network. All other sub basestations will listen for the message stream from the current master to determine where the network is in the cycle. The next basestation to assume the role of master (secondary master) will adopt the MAC address of the last master (primary master) basestation and use the hopping sequence from the primary master. FIG. 34 illustrates one exemplary embodiment of the redundant basestation message stream.
The secondary masters preferably log onto the network using the same technique as the field units and are assigned positions to handle within the message stream. Until secondary masters join the network, the primary master handles the entire message stream. FIG. 35 shows a message stream with only one basestation. As more basestations log onto the system, the primary master assigns the secondary basestations positions within the message stream (FIG. 36). If later a basestation becomes inoperable and its messages can no longer be heard by other basestations on the network, the previous basestation can take its position. FIG. 37 illustrates a message stream where basestation two becomes inoperable and basestation one assumes its duties.
In systems containing multiple basestations, the data from each basestation is preferably collected by a data collector/concentration element. In one embodiment, the data collector is a PC or an embedded device. FIG. 38 shows a schematic of multiple basestations connected with a data collector.
A further understanding of the invention may be attained by reference to copending, commonly assigned U.S. patent application Ser. No. ______, Express Mail Label No. EV 324 849 470 US) entitled “Industrial Wireless Network With Message Authentication,” filed this same day herewith, the teachings of which are incorporated herein by reference. A further understanding of one embodiment of the invention may be attained by reference to aforementioned incorporated-by-reference U.S. patent application Ser. No. 10/449,455, filed May 30, 2003, entitled “Non-Interfering Multipath Communications Systems.” One skilled in the art will appreciate further features and advantages of the invention based on the above-described embodiments. Accordingly, the invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.

Claims

1. A process control and monitoring system for wirelessly communicating with multiple devices, the system comprising:

a. a basestation that communicates with multiple field units via a wireless signal and in accordance with a wireless protocol;

b. multiple field units that receive wireless signals in accordance with the wireless protocol from the basestation and respond to requests from the basestation via wireless signals in accordance with the wireless protocol; and

c. wherein the wireless protocol includes frames defined by multiple time slots including,

i. an initial time slot reserved for a wireless start-frame message from the basestation to multiple field units, the wireless start-frame message from the basestation assigning the remaining time slots to field units, and providing information for synchronizing the basestation and the field units, and

ii. a later time slot reserved for a wireless message from a field unit to the basestation.

2. The system of claim 1, wherein the wireless start-frame message has a header portion, a data portion, and an error detection and correction portion.

3. The system of claim 1, wherein the start-frame wireless message contains information about the number of frames and the frame number.

4. The system of claim 1, wherein the wireless messages communicated by the basestation and the field units include unique identifiers.

5. The system of claim 1, wherein the wireless start-frame message from the basestation informs the field unit when their assigned time slot will occur.

6. The system of claim 1, wherein the frequency of the wireless signals used by the basestation and the field units are in the range of about 902 MHz to 928 MHz.

7. The system of claim 1, wherein additional communication between the basestation and the field units is in the form of wireless messages having a header portion, a data portion, and an error detection and correction portion.

8. The system of claim 7, wherein the header portion of the wireless messages from the basestation includes a unique identifier for indicating with which field unit the basestation is attempting to communicate.

9. The system of claim 7, wherein the field units are capable of sending data related to a manufacturing process to the basestation via the wireless messages when requested by the basestation.

10. The system of claim 1, wherein the field units are capable of controlling the parameters of a process when directed by the basestation via the wireless messages.

11. The system of claim 1, wherein the system includes multiple basestations.

12. The system of claim 11, wherein multiple basestations send and receive wireless messages from the field units during different time periods.

13. The system of claim 1, wherein the start-frame wireless message directs at least one of the field units to listen to future messages for data.

14. The system of claim 1, wherein the start-frame message acknowledges an earlier message sent by a field unit.

15. A process control and monitoring system for wirelessly communicating with multiple devices, the system comprising:

i. an initial time slot reserved for a start-frame wireless message from the basestation to multiple field units, the start-frame wireless message from the basestation indicates which field unit is assigned to which of the remaining time slots, and

ii. later time slots. reserved for wireless messages from multiple field units to the basestation.

16. A process control and monitoring system for wirelessly communicating with multiple devices, the system comprising;

a. a basestation that wirelessly communicates with multiple field units in accordance with a wireless protocol;

i. an initial time slot reserved for a start-frame wireless message from the basestation, the start-frame wireless message indicating to the field units that multiple time slots within the frame are available for logon requests by field units, and

ii. a later time slot for wireless logon request messages from the field units.

17. The system of claim 16, wherein a time slot, after the time slot for wireless logon request messages from the field units, is reserved for a wireless message from the basestation to any field unit which sends a wireless logon request message.

18. A process control and monitoring system for wirelessly communicating with multiple devices, the system comprising:

c. wherein the wireless protocol includes frames defined by multiple time slots including an initial time slot reserved for at least a portion of a start-frame wireless message from the basestation, the start-frame wireless message directing multiple field units to send data in assigned time slots.

19. The system of claim 18, wherein the start-frame wireless message overrides a selection of data normally sent by a field unit.

20. The system of claim 18, wherein the start-frame wireless message directs at least one of the field units to listen to future messages for data.

21. The system of claim 18, wherein the start-frame message acknowledges an earlier message sent by a field unit.

22. A process control and monitoring basestation for wirelessly communicating with multiple devices, the system comprising:

a. a basestation for communicating with and controlling multiple field units via a wireless signal and in accordance with a wireless protocol;

b. wireless communication and control messages from the basestation sent via a wireless protocol that includes frames defined by multiple time slots; and

c. an initial time slot reserved for a wireless start-frame message from the basestation, the wireless start-frame message from the basestation assigning the remaining time slots, and providing information for synchronizing with the wireless communication and control messages.

23. The basestation of claim 22, wherein a header portion of the wireless start frame message from the basestation includes a unique identifier for indicating with which field unit the basestation is attempting to communicate.

24. The basestation of claim 22, wherein the basestation requests data related to a manufacturing process via the wireless communication and control messages.

25. The basestation controls parameters of a manufacturing process via he wireless communication and control messages.

26. Process control and monitoring field units for wirelessly communicating with multiple devices, the system comprising;

a. multiple field units that receive wireless communication and control messages in accordance with wireless protocol and respond to requests via wireless signals in accordance with a wireless protocol;

b. wireless communication and control messages sent via a wireless protocol that includes frames defined by multiple time slots; and

c. an initial time slot reserved for a wireless start-frame message for communicating with the multiple field units, the wireless start-frame message assigning the remaining time slots to different field units, and providing information synchronizing the field units with the wireless communication and control messages.