Honeywell International Inc.

Honeywell G.m.b.h.

Norman Raymond Swanson

Paul Francis McLaughlin

Christopher Pulini

Prasad Samudrala

Joseph Pradeep Felix

Channabasavaraj Raravi

Alexander Chernoguzov

Jason Thomas Urso

Niral B Sanghavi

James Michael Schreder

Jethro F Steinman

Amol Gandhi

John J Rosa-Bian

Ashish Sharma

Brian Reynolds

Cathleen F Kilpatrick

Gary Drayton

Jeffrey B Scott

Sandeep Rudraraju

Sunil S Bale

William Osei-Bonsu

Karthikeya S Ramanathan

Pekka M Salpakari

Jay M Doyle

Udaya Shetty

Markku K Vaat&auml;inen

Methods and systems for synchronizing controllers in an automation control system, can involve arranging redundancy elements in an automation control system comprising a group of nodes, wherein the redundancy elements can include one or more primary controllers and a group of concurrent secondary controllers, and wherein a back-up to the primary controller can exist on any node. Such methods and systems can further involve backing-up of the primary controller by the one or more secondary controllers to allow the primary controller to maintain the one or more secondary controllers as a new, alternate secondary controller for a load balancing or an equipment update.

Multi-synch of a primary automation device with multiple secondaries

A method of fault-tolerant process control includes providing a network process control system in an industrial processing facility (IPF) including a plant-wide network coupling a server to computing platforms each including computing hardware and memory hosting a software application for simultaneously supporting a process controller and another process controller or an I/O gateway. The computing platforms are coupled together by a private path redundancy network for providing a hardware resource pool. At least some of the computing platforms are directly coupled by an I/O mesh network to a plurality of I/O devices to field devices that are coupled to processing equipment. Upon detecting at least one failing device in the hardware resource pool, over the private path redundancy network a backup is placed into service for the failing device from the another process controller or I/O gateway that is at another of the computing platforms in the hardware resource pool.

Redundant controllers or input-output gateways without dedicated hardware

A method for use by a first device associated with a redundant second device includes issuing a synchronization request to a file system of the first device. The file system is configured to cache changes associated with a memory space of an application, the synchronization request causing the file system to send the cached changes to a driver of the first device The driver is used to commit the cached changes to a copy of the memory space of the application in order to cause the copy of the memory space of the application to match the memory space of the application. One or more changes made to the copy of the memory space of the application caused by committing the cached changes are identified. A change set identifying the one or more changes being made to the copy of the memory space of the application is created in a buffer and the change set transmitted from the buffer to the second device in order to synchronize an additional copy of the memory space of the application at the second device.

Apparatus and method for implementing process control redundancy using operating system (OS) file system support

A method includes installing new communication interfaces in first process controllers of an industrial process control and automation system. The first process controllers are configured to communicate over a first supervisory network, and the communication interfaces are configured to communicate over a second supervisory network of a different type. The method also includes migrating the first process controllers to second process controllers of a different type while maintaining control over an industrial process being controlled by the first process controllers. The second process controllers are configured to communicate over the second supervisory network.

Methods for on-process migration from one type of process control device to different type of process control device

A method for bandwidth management in a wireless network having wireless field devices (FDs) wirelessly coupled to a wireless access point associated to a wireless gateway. A first bandwidth usage percentage (BUP) consumed by the wireless access point and wireless router(s) is calculated from summed connected device weights. In response to a new FD or wireless router requesting to be connected to the network, a second BUP is calculated that would be consumed by the wireless access point and the wireless router(s) if the new FD or wireless router were connected to the wireless network. If the second BUP is not less than respective BUP thresholds, the new FD or router is prevented from being connected to the network. Disclosed bandwidth management can also be applied if an already connected FD in the network changes its path from one router or access point to another connected router or access point.

Bandwidth management in a wireless network

A method includes receiving data from multiple wireless field devices using multiple wireless communication protocols. The method also includes normalizing the data from the wireless field devices using one or more templates associated with the wireless field devices. The method further includes transmitting the normalized data in a unified format. The method could also include generating the one or more templates using device description (DD) files associated with the wireless field devices. Each template may provide, for one wireless field device or type of wireless field device, (i) an indication of a type of data provided by the wireless field device or type of wireless field device, (ii) a range of data provided by the wireless field device or type of wireless field device, and (iii) how to normalize data from the wireless field device or type of wireless field device into the unified format.

Apparatus and method for providing a common interface for multiple wireless communication protocols

Methods and systems are disclosed herein for accurately calculating battery consumption in a wireless field device. The total current consumed by a radio board associated with a wireless field device can be determined based on the sum of the current consumed as a result of particular events occurring at the radio board. The current consumed by a sensor board of the wireless field device can then be averated with respect to particular type of sensor. The current consumed by the radio board and the current consumed by the sensor board in the wireless field device can be combined to calculate a predictive value indicative of a remaining life of a battery associated with the wireless field device.

Method and system for calculating accurate battery percentage usage in wireless field devices

A method includes identifying multiple statistics associated with each of multiple wireless connections. The multiple wireless connections form a single communication path between two wireless nodes in a wireless network. The method also includes identifying an overall quality associated with the communication path using the statistics. The method can also include assigning a quality value to each statistic for each wireless connection, where the overall quality is based on at least one of the quality values assigned to the statistics (such as a lowest of the quality values). The statistics could include a Received Signal Quality Indicator (RSQI), a Received Signal Strength Indication (RSSI), and a transmit success/fail ratio. The quality value assigned to each statistic could include a 'good' quality, a 'fair' quality, or a &#x201c;poor&#x201d; quality.

Apparatus and method for reporting of communication path quality within a wireless network

A method includes identifying an amount of time that a wireless device has or does not have redundant connectivity in a wireless network during a specified time period. The method also includes identifying a redundant wireless connection availability of the wireless device during the specified time period. Identifying the amount of time that the wireless device has or does not have redundant connectivity could include identifying connection events associated with the wireless device. The connection events can include events in which a wireless connection with the wireless device is formed and events in which a wireless connection with the wireless device is dropped. Time periods during which multiple wireless connections with the wireless device exist or do not exist can be identified. Identifying the redundant wireless connection availability could include identifying a percentage of the specified time period during which multiple wireless connections with the wireless device exist.

Apparatus and method for measuring and reporting redundant wireless connectivity over time

A method includes receiving link quality information associated with multiple wireless connections in a wireless network. The method also includes identifying at least one asymmetric communication path in the wireless network using the link quality information. The link quality information could include a statistical value for each of the wireless connections. Identifying the at least one asymmetric communication path could include identifying a first and a second of the statistical values associated with a first and a second of the wireless connections, respectively, and determining whether a difference between the first and second statistical values exceeds a threshold. The method could further include applying a heuristic to indicate that the first and second wireless connections do not form an asymmetric communication path even if the difference between the first and second statistical values exceeds the threshold.

Apparatus and method for maintaining reliability of wireless network having asymmetric or other low quality wireless links

A method includes synchronizing a first gateway with information from a second gateway. The second gateway operates in a primary role with at least one primary network address. The second gateway communicates with at least one wireless device that uses at least one encryption key during at least one secure communication session. The information includes the at least one encryption key. The method also includes detecting a switchover event at the first gateway. The method further includes, in response to detecting the switchover event, switching the first gateway to the primary role, communicating using the at least one primary network address, and maintaining the at least one secure communication session at the first gateway after the first gateway switches to the primary role.

Gateway supporting transparent redundancy in process control systems and other systems and related method

A method includes receiving a request to install a software release, where the software release is to be installed on a first device and/or a second device. The method also includes initiating installation of the software release on the second device and determining whether or not a user wishes to continue with the installation of the software release. The method further includes initiating installation of the software release on the first device if the user wishes to continue. In addition, the method includes restoring a second software release on the second device if the user does not wish to continue. The first and second devices may represent redundant devices, such as a redundant set of controllers in a process control system or a redundant set of I/O modules that facilitate communication between one or more controllers and one or more process elements in the process control system.

Apparatus and method for allowing a fail-back to a prior software release in a process control system

A system for, and method of, disseminating a functional block to a redundant controller for a real-time process control system and a real-time process control system incorporating the system or the method. In one embodiment, the system includes: (1) a dynamically linkable library object associable with the functional block and (2) a shared memory, associated with at least two nodes of the redundant controller, that receives the dynamically linkable library object and the functional block and provides concurrent access thereto by both the at least two nodes to ensure consistent memory images therefore without requiring one of the at least two nodes to be taken off-line.

System and method for disseminating functional blocks to an on-line redundant controller

There is disclosed a redundant process controller for use in a process facility having a plurality of process systems that produce process data, wherein the process data are gathered by process controllers associated with the process systems and are exchanged by the process controllers via a network. The redundant process controller is associated with a first selected process system and is capable of receiving process data from at least one remote process controller and intermittently transferring the received process data to the first selected process system. The redundant process controller comprises 1) a primary process controller capable of storing the received process data, wherein the primary process controller transmits the received process data to the first selected process system; and 2) a secondary process controller capable of storing the received process data, wherein the secondary process controller detects failures in the primary process controller and, upon detection of a failure, transmits to the first selected process system the received process data in lieu of the primary process controller.

Systems and methods for minimizing peer-to-peer control disruption during fail-over in a system of redundant controllers

There is disclosed a system and method for maintaining data coherency between a primary process controller operable to execute process control tasks and a backup process controller operable to replace the primary process controller upon failure, wherein the primary process controller cyclically executes the process control tasks during base control cycles having a period, T. The system comprises 1) a tracking circuit operable to detect changed data in a main memory in the primary process controller; 2) a data buffer for temporarily storing the changed data; and 3) data transfer circuitry for transferring the changed data in the data buffer to a backup memory in the backup process controller at least once during each base control cycle of the primary process controller, such that the transfer of changed data does not interfere with execution of the process control tasks.

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Doylestown, PA, United States of America

Norman Raymond Swanson