Methods and apparatus for control using control devices that provide a virtual machine environment and that communicate via an ip network

Abstract

The invention provides improved methods and apparatus for control using field and control devices that provide a virtual machine environment and that communicate via an IP network. By way of non-limiting example, such field device can be an “intelligent” transmitter or actuator that includes a low power processor, along with a random access memory, a read-only memory, FlashRAM, and a sensor interface. The processor can execute a real-time operating system, as well as a Java virtual machine (JVM). Java byte code executes in the JVM to configure the field device to perform typical process control functions, e.g., for proportional integral derivative (PID) control and signal conditioning. Control networks can include a plurality of such field and control devices interconnected by an IP network, such as an Ethernet.

1 - 228 . (canceled) 
   
   
       229 . A device for use in a control system, comprising:
 a controller having a powered Ethernet connection and at least one communication connection,   the powered Ethernet connection adapted to provide power to the controller from a control network, and   the at least one communication connection adapted to provide for communication with at least one field device.   
   
   
       230 . The device of  claim 229 , wherein the communication connection is a bus connection. 
   
   
       231 . The device of  claim 230 , wherein the bus connection is adapted to provide for communication with a field device via a bus operating in substantial accord with a protocol selected from the group consisting of: Foundation Fieldbus, Foxcomm, Profibus, ControlNet, Modbus, Devicenet, HART, NodeBus, LonWorks. 
   
   
       232 . The device of  claim 229 , wherein the communication connection is an Ethernet connection. 
   
   
       233 . The device of  claim 229 , wherein the controller further comprises a processor adapted to execute a control algorithm to control the at least one field device. 
   
   
       234 . The device of  claim 229 , further comprising a first I/O card comprising the powered Ethernet connection and a second I/O card comprising the at least one communication connection. 
   
   
       235 . The device of  claim 229 , wherein the device is coupled for communication with a control device adapted to monitor and control aspects of a process. 
   
   
       236 . The device of  claim 229 , wherein the device functions at the direction of a plant-level processor. 
   
   
       237 . The device of  claim 229 , wherein the at least one communication connection provides power to the at least one field device. 
   
   
       238 . The device of  claim 237 , wherein the at least one field device includes a sensing element and the device includes a pair of wires providing excitation to the sensing element. 
   
   
       239 . The device of  claim 229 , wherein the field device obtains power via the at least one communication connection and via the powered Ethernet connection. 
   
   
       240 . The device of  claim 229 , wherein the device is coupled for communication via one or more networks. 
   
   
       241 . The device of  claim 240 , wherein the device further comprises a device integrator adapted to provide communication between a plurality of the one or more networks. 
   
   
       242 . The device of  claim 240 , wherein the controller is coupled for communication with one or more control devices disposed on the one or more networks and adapted to monitor and control aspects of a process. 
   
   
       243 . The device of  claim 229 , further comprising one or more networked I/O modules for providing interoperability between control systems. 
   
   
       244 . The device of  claim 229 , wherein the at least one communication connection comprises at least two communication connections operating according to different protocols from one another. 
   
   
       245 . A system for monitoring and controlling a process, comprising:
 a field device;   a control device; and   a networked device coupled for communication with the control device via a powered Ethernet connection and coupled for communication with the field device via at least one communication connection,   wherein the field device receives power via the communication connection and the networked device receives power via the powered Ethernet connection.   
   
   
       246 . The system of  claim 245 , wherein the control device is selected from the group consisting of: workstation, enterprise server, plant server, controller, personal computer, handheld computer, and integrator. 
   
   
       247 . The system of  claim 245 , wherein the networked device comprises a controller adapted to communicate with the control device and the field device. 
   
   
       248 . The system of  claim 245 , further comprising a powered Ethernet hub coupled between the control device and the networked device and adapted to provide power to the networked device. 
   
   
       249 . A device for a process control system, comprising:
 a powered Ethernet connection adapted to provide power to the device and a communication connection adapted to provide for communication with a field device via a communication link that provides power to the field device.   
   
   
       250 . The device of  claim 249 , wherein the device further includes a first network I/O card for providing the powered Ethernet connection and a second network I/O card for providing the communication connection. 
   
   
       251 . The device of  claim 249 , wherein the device further comprises:
 a processor for implementing station management software and for communicating with a control device adapted to monitor and control aspects of a process and a field device; and   a memory for storing data.   
   
   
       252 . A control device for a system, comprising:
 a powered Ethernet connection for communicating with a control network, the powered Ethernet connection providing power to the control device; and   a processor that executes a control algorithm to control one or more field devices associated with the control device.   
   
   
       253 . The control device of  claim 252 , wherein the field devices are sensing devices adapted to sense any of (i) an environmental condition and (ii) a physical condition, the physical condition comprising any of temperature, pressure, flow, position. 
   
   
       254 . The control device of  claim 252 , wherein the field devices are actuators adapted to control a mechanism affecting a physical condition of an environment. 
   
   
       255 . The control device of  claim 254 , wherein the mechanism comprises any of a valve, paddle, inlet, outlet. 
   
   
       256 . The control device of  claim 252 , wherein the processor further executes another control algorithm that at least one of (i) maintains the system at a desired level, and (ii) drives it to that level as a function of one or more measured values and one or more setpoints. 
   
   
       257 . The control device of  claim 252 , wherein the processor further executes station management software adapted to allow the control device to report on any of health information, performance information, and status information. 
   
   
       258 . The control device of  claim 252 , further comprising:
 a bus connection for communicating with one or more field devices via a bus operating in substantial accord with a protocol selected from the group consisting of: Foundation Fieldbus, Foxcomm, Profibus, ControlNet, Modbus, Devicenet, HART, NodeBus, LonWorks.   
   
   
       259 . A field device for a control system, comprising:
 a powered Ethernet interface for communicating with a control network, the powered Ethernet connection providing power to the field device; and   an interface to any of (i) a sensor and (ii) an actuator, for controlling and collecting information therefrom.   
   
   
       260 . The field device of  claim 259 , wherein the interface is to a sensor adapted to sense any of (i) an environmental condition and (ii) a physical condition, the physical condition comprising any of temperature, pressure, flow, position. 
   
   
       261 . The field device of  claim 259 , wherein the interface is to an actuator adapted to control a mechanism affecting the physical condition of an environment. 
   
   
       262 . The field device of  claim 259 , further comprising a serial interface adapted to allow attachment of the field device to a bus operating in substantial accord with a protocol different than that of the control network. 
   
   
       263 . The field device of  claim 259 , wherein the field device communicates with a control device via the powered Ethernet connection. 
   
   
       264 . A system, comprising:
 a controller coupled for communication over a control network operating in an Ethernet protocol;   a powered Ethernet interface coupled to the control network;   a sensing apparatus adapted to sense a physical condition and coupled to the powered Ethernet interface for communicating about the sensed physical condition with the controller,   wherein the powered Ethernet connection provides power to the sensing apparatus.   
   
   
       265 . The system of  claim 264 , wherein the sensed physical condition comprises any of temperature, pressure, flow, position. 
   
   
       266 . The system of  claim 264 , wherein the sensed physical condition relates to an environmental factor, and the controller executes a control algorithm to maintain the environmental factor. 
   
   
       267 . The system of  claim 266 , wherein the environmental factor applies to any of a residential facility, commercial facility, industrial facility. 
   
   
       268 . The system of  claim 264 , wherein the controller comprises a processor that executes a control algorithm that at least one of (i) maintains the system at a desired level, and (ii) drives it to that level as a function of one or more measured values and one or more setpoints. 
   
   
       269 . The system of  claim 264 , wherein the controller comprises a processor that executes station management software adapted to allow the controller device to report on any of health information, performance information, and status information. 
   
   
       270 . A system, comprising:
 a controller coupled for communication over a control network operating in an Ethernet protocol and adapted to transmit control signals over the control network;   a powered Ethernet interface coupled to the control network; and   a field device that comprises any of:
 (i) a positioner coupled to the powered Ethernet interface for receiving control signals from the controller and drawing power from the Ethernet interface, and 
 (ii) an actuator adapted to control a mechanism to affect the physical condition of an environment and coupled to the powered Ethernet interface for receiving control signals from the controller, the actuator adapted to draw power from the Ethernet interface. 
   
   
   
       271 . The system of  claim 270 , wherein the field device comprises an actuator adapted to control a mechanism that comprises any of a valve, paddle, inlet, outlet. 
   
   
       272 . The control system of  claim 270 , wherein the field device comprises a positioner that includes a position sensor and that is adapted to communicate information relating to the position of a controlled element. 
   
   
       273 . The control system of  claim 270 , wherein the field device comprises a positioner adapted to control a motor. 
   
   
       274 . A transmitter device, comprising:
 an Ethernet interface configured to communicate over a network according to an Ethernet protocol;   power circuitry operable to extract operating power from the Ethernet interface;   a sensor interface configured to communicate with a sensing device adapted to sense a physical condition;   a processor operable to receive a sensing device communication corresponding to a sensed physical condition and to communicate with a control device via the Ethernet interface about the sensed physical condition.   
   
   
       275 . The transmitter device of  claim 274 , wherein the sensed physical condition corresponds to an environmental factor. 
   
   
       276 . The transmitter device of  claim 274 , wherein the physical condition is any of temperature, pressure, flow. 
   
   
       277 . An actuating device, comprising:
 an Ethernet interface configured to communicate over a network operating according to an Ethernet protocol;   power circuitry operable to extract operating power from the Ethernet interface;   a processor operable to control a mechanism that affects a physical condition of an environment and to communicate via the Ethernet interface about the mechanism.   
   
   
       278 . The actuating device of  claim 277 , wherein the actuating device controls a mechanism that comprises any of a valve, paddle, inlet, outlet. 
   
   
       279 . The actuating device of  claim 277 , wherein the physical condition is any of temperature, pressure, flow.