Publish/subscribe protocol for real-time process control

Patent metadata

Field	Value
Publication number	US-11747797-B2
Application number	US-202117563413-A
Country	US
Kind code	B2
Filing date	Dec 28, 2021
Priority date	Jun 10, 2019
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

A Multi-Purpose Dynamic Simulation and run-time Control platform includes a virtual process environment coupled to a physical process environment, where components/nodes of the virtual and physical process environments cooperate to dynamically perform run-time process control of an industrial process plant and/or simulations thereof. Virtual components may include virtual run-time nodes and/or simulated nodes. The MPDSC includes an I/O Switch which delivers I/O data between virtual and/or physical nodes, e.g., by using publish/subscribe mechanisms, thereby virtualizing physical I/O process data delivery. Nodes serviced by the I/O Switch may include respective component behavior modules that are unaware as to whether or not they are being utilized on a virtual or physical node. Simulations may be performed in real-time and even in conjunction with run-time operations of the plant, and/or simulations may be manipulated as desired (speed, values, administration, etc.). The platform simultaneously supports simulation and run-time operations and interactions/intersections therebetween.

First claim

What is claimed:

1. A method of controlling an industrial process of an industrial process plant, the method comprising:
during run-time operations of the industrial process plant, executing a process control loop of a process control system of the industrial plant, the process control loop including a field device disposed in a physical environment of the industrial process plant, a process controller, and an I/O node communicatively connecting the field device and the process controller, and the executing of the process control loop including:
generating, by the field device, a first publication, the first publication indicating data content generated by a component behavior module of the field device based on the field device performing a physical function;
publishing, by the field device via a publication/subscription layer of the field device, the first publication in a real-time control protocol to a real-time control network, the first publication subscribed to by the I/O node;
receiving, by the field device via the publication/subscription layer of the field device and the real-time control network, a second publication in the real-time control protocol, the second publication published by the I/O node via a respective publication/subscription layer, subscribed to by the field device, and including instructions generated by the process controller responsive to the data content generated by the field device and published in a third publication in the real-time control protocol to the real-time control network, the third publication subscribed to by the I/O node and published by the process controller via a respective publication/subscription layer; and
modifying a behavior of the field device responsive to the instructions included in the second publication, thereby controlling at least a portion of the industrial process, the modifying including determining, by the component behavior module, the modification to the field device based on the instructions included in the second publication.

2. The method of claim 1 , wherein:
generating the first publication indicating the data content generated by the field device comprises including, in the first publication, an identifier of the data content, the identifier of the data content included in a set of unique routing identifiers utilized by the I/O node;
the set of unique routing identifiers is based on one or more system configuration databases of the process control system; and
the I/O node determines that the process controller is a recipient of the data content generated by the field device based on the identifier of the data content included in the first publication.

3. The method of claim 1 , wherein:
generating the first publication indicating the data content generated by the field device comprises including, in the first publication, an identifier of the field device, the identifier of the field device included in a set of unique routing identifiers utilized by the I/O node, and the set of unique routing identifiers based on one or more system configuration databases of the process control system; and
the I/O node determines that the process controller is a recipient of the data content of the field device based on the identifier of the field device included in the first publication.

4. The method of claim 1 , wherein:
the I/O node determines that the field device is a recipient of the instructions published by the process controller based on at least one of: (i) an identifier indicative of the field device or (ii) an identifier indicative of the field device, the at least one of (i) the identifier indicative of the field device or (ii) the identifier indicative of the field device included in the third publication and included in a set of unique routing identifiers utilized by the I/O node, the set of unique routing identifiers based on one or more system configuration databases of the process control system; and
receiving the second publication published by the I/O node and subscribed to by the field device is based on the at least one of (i) the identifier indicative of the field device or (ii) the identifier indicative of the field device.

5. The method of claim 1 , wherein:
the field device further includes a virtual process input/output (PIO) subsystem disposed between the component behavior module and the publication/subscription layer of the field device;
publishing the first publication indicating the data content generated by the field device via the publication/subscription layer comprises publishing, by the virtual PIO subsystem, the data content generated by the component behavior module of the field device to the publication/subscription layer; and
receiving the second publication including the instructions generated by the process controller via the publication/subscription layer includes receiving, by the virtual PIO subsystem, the second publication from the publication/subscription layer and providing the instructions generated by the process controller and included in the second publication to the component behavior module using an I/O type native to the component behavior module.

6. The method of claim 1 , wherein the process controller is a virtual process controller disposed in a virtual environment of the industrial process plant; and
the I/O node is an I/O switch communicatively connecting the virtual environment of the industrial process plant and the physical environment of the industrial process plant.

7. The method of claim 1 , wherein the process controller is a physical process controller disposed in the physical environment of the industrial process plant.

8. A field device included in a real-time control network of a process control system of an industrial process plant, the field device comprising:
a physical component operable to perform a physical function corresponding to an industrial process;
a publication/subscription layer communicatively connecting the field device to an I/O node;
one or more processors; and
one or more memories storing a component behavior module and computer-executable instructions that, when executed by the one or more processors, cause the field device to, during run-time operations of the industrial process plant:
publish, via the publication/subscription layer, a first publication in a real-time control protocol to the real-time control network, the first publication subscribed to by the I/O node and including data content generated by the component behavior module based on the physical component of the field device performing the physical function;
receive, via the publication/subscription layer and the real-time control network, a second publication in the real-time control protocol, the second publication published by the I/O node via a respective publication/subscription layer, subscribed to by the field device, and including instructions generated by the process controller and published, to the real-time control network, in a third publication in the real-time control protocol responsive to the data generated by the field device, the third publication subscribed to by the I/O node and published by the process controller via a respective publication/subscription layer; and
modify a behavior of the field device to thereby control at least a portion of the industrial process, the modification of the behavior of the field device determined by the component behavior module in response to the instructions included in the second publication.

9. The field device of claim 8 , wherein:
the first publication includes an identifier of the data generated by the field device;
the identifier of the data is included in a set of unique routing identifiers utilized by the I/O node, the set of unique r

Assignees

• Fisher Rosemount Systems Inc

Inventors

• Nixon Mark J
• Amaro Jr Anthony
• Bell Noel Howard
• Caldwell John M
• Law Gary K

Classifications

• G05B19/41885 Primary

  characterised by modeling, simulation of the manufacturing system · CPC title

• G05B19/4183

  characterised by data acquisition, e.g. workpiece identification · CPC title

• G05B19/4185 Primary

  characterised by the network communication · CPC title

• G05B19/41835

  characterised by program execution · CPC title

• G05B19/41845

  characterised by system universality, reconfigurability, modularity · CPC title