Abstract:
An industrial control system includes a central controller having a memory containing programmable data including operating programs for operating the controller, control program for controlling an industrial process, and configuration data configuring values used by the operating program and control program. The central controller is designed to control multiple devices also having memory holding programmable data including operating programs and configuration data. A program is executable by the central controller that causes the central controller to identify memories distributed through the industrial control system having programmable data and collect the programmable data from the memories. Accordingly, the collected programmable data may be used to substantially recreate operation of the industrial control system in a second industrial control system having another central controller substantially identical to the industrial controller and multiple devices connected to the central controller.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is based on provisional application 60/650,325 filed Feb. 4, 2005, and entitled “ControlLogix Firmware Supervisor” and claims the benefit thereof. 

   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
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   BACKGROUND OF THE INVENTION 
   The present invention relates generally to industrial control systems and, more particularly, to a system and method for automatically updating data of devices within an industrial control system. Using the invention, an industrial control system may be efficiently cloned or a given industrial control system may automatically maintain desired firmware versions and programmable data on devices distributed across the industrial control system. 
   Industrial control systems are used in a variety of automation applications, such as manufacturing and materials handling. Referring to  FIG. 1 , an industrial control system  1  includes an industrial controller  2  in communication with a plurality of I/O modules  3  through a backplane  4 . The industrial controller  2  is also in communication with a plurality of additional devices that may include network storage devices  5 , an overload relay  6 , a network expander  7 , and an interface  8  for integrating additional components, such as a third-party scale  9 . To facilitate communication with these components  5 ,  6 ,  7 ,  8 ,  9 , the industrial control system  1  includes one or more network controllers  10 , such as Ethernet controllers, DeviceNet controllers, ControlNet controllers, FireWire controllers, or FieldBus controllers that allow communication over one or more communication lines  11 . Therefore, the industrial controller  2  can control a variety of devices, generally designated  12 , that may include I/O modules  3  and additional components  5 ,  6 ,  7 ,  8 ,  9 . The industrial controller  2 , network controllers  10 , and devices  12  are powered by respective power supplies  13 . 
   Referring now to  FIG. 2 , the industrial control system  1  includes a variety of software. In general, the industrial controller  2  includes an operating system  14  that controls the operation of the industrial controller  2 , operational programs  15  that are executed by the industrial controller  2  to operate the industrial control system  1 , configuration data  16  that forms a record of user-selected preferences, and a device list  17  that serves as a map of devices, device types, and locations of all devices within the industrial control system  1 . As will be described, the industrial controller  2  relies upon each piece of software  14 ,  15 ,  16 ,  17  to generate commands that are communicated to each of the devices within the industrial control system  1  to control operation of the industrial control system  1 . In this regard, each device  12  includes firmware  18  and configuration data  19  that, as will be described, allows the device  12  to execute the commands received from the industrial controller  2  in the manner desired. 
   When the industrial controller  2  executes the operational program  15 , the operating system  14  and configuration data  16  are used to generate commands that are communicated to the devices  12  using the device list  17 . When received by a particular device  12 , the device  12  uses the firmware  18  and the configuration data  19  to interpret and carryout the instructions contained in the commands. In this regard, the firmware  18  and the configuration data  19  controls how the device  12  interprets the commands and translates those commands into actions taken by device  12 . 
   Referring now to  FIG. 3 , the firmware  18  and configuration data  19  form one of the three fundamental characteristics of an industrial control system. In particular, the firmware  18  and configuration data  19  form individual programmable data  20  or data that is specific to a particular device. The individual programmable data  20  is distinguishable from software programs  21 , such as operational programs  15  used by the industrial controller, that form the second characteristic of an industrial control system. As will be described, in traditional industrial control system, the operating system  14  of the industrial controller is generally treated similarly to the operational programs  15 , as are configuration data  16  and other software information stored locally in the industrial controller. Accordingly, these software components are all associated with software programs  21 . 
   The individual programmable data  20  is also distinguishable from the third characteristic of industrial control systems, hardware information  22 . The hardware information  22  may include information such as industrial controller type, individual module types, backplane type, communication network types, and the like. This information is used by the industrial controller to identify components in the industrial control system and communicate commands accordingly. In particular, this information generally forms the information stored as the device list  17  of  FIG. 2   
   Referring now to  FIGS. 1 through 3 , it has been recognized that in order for an industrial control system to operate properly, the specifics of the hardware information  22 , software programs  21 , and individual programmable data  20  must work together. Accordingly, when building, changing, or updating the devices  12  of the industrial control system  1 , a programmer uses a computer  23  having a direct communications link  24  to the industrial controller  1  or, alternatively, a remote communications link  25  through a remote-access modem  26  to the industrial controller  1 . Though this communications link  24 / 25 , the user can configure the individual components of the industrial control system  1  to communicate and execute as desired. To do so, specialized software is executed on the computer  23  to communicate with the industrial controller  1  and the devices  12  of the industrial control system  1  and compile an accurate listing of the characteristics of each device  12  in the industrial control system  1  and how it is connected. That is, the programmer uses the computer  23  to identify the hardware information  22  and the individual programmable data. For example, programs such as RSLogix 5000, commercial available from Rockwell Automation, 1201 S. Second St., Milwaukee, Wis. 53204, may be utilized to perform these programming procedures. 
   Once the specific characteristics of each element of the industrial control system  1  is known, the programmer can then use the computer  23  and the specialized software to develop the software programs  21 , for example the operational program  15 , to operate the industrial control system  1 . For example, by knowing the specific programmable data  20  and hardware information  22  of a given device  12 , the programmer can compile the commands required to cause the device  12  to operate in the manner desired. That is, since the manner in which a given device  12  will interpret a command and the actions taken in response to such a command are dictated by the configuration data  18  and the firmware  19  of the device  12 , the instructions should consider the particular characteristics of the device  12 . Once the initial compilation of the operating program  15  has been completed, the programmer transfers it from the computer  23  to the industrial controller  2 . 
   In an effort to backup and protect these highly specialized programs, some industrial controllers  2  include a port  28  configured to receive a removable storage medium  30 , such as a compact flash card. The removable storage medium  30  may be inserted into the port  28  whereby the software programs  21  developed on the computer  23  and downloaded onto the industrial controller  2  can be automatically backed up onto the removable storage medium  30 . Similarly, in some industrial controllers  2 , the hardware information  22  stored on the industrial controller  2  may be backed up onto the removable storage medium  30 . In this regard, some industrial controllers  2  are designed to backup all the information stored on the industrial controller onto the removable storage medium  30 . 
   However, as industrial control systems  1  have evolved, they increasingly rely upon distributed intelligence. That is, much of the information processing and configuration data is not stored in the industrial controller  2  alone. Rather, a fair amount of the information traditionally stored in the industrial controller  2  has been distributed across the devices  12  of the industrial control system  1 . As such, the individual programmable data  20  of each device  12  has gained added importance in governing the overall functionality of the industrial control system  1 . 
   In this regard, it may be necessary to adjust the programmable data of a device  12 , for example, changing firmware  19  or setting the configuration data  18 , so that device  12  will properly respond to commands sent by the industrial controller  1 . In this regard, the programmer can use the computer  23  and software, such as Firmware Supervisor, commercial available from Rockwell Automation, to reconfigure the programmable data of the device  12 . 
   For example, if the device  12  is a scale  9 , the configuration data  18  may be set to indicate an overweight condition at 1,500 pounds (lbs) and the firmware of the scale  9  may be configured to send an alarm to the industrial controller  2  whenever the scale  9  indicates an undesired weight. Accordingly, the operational program  15  may be designed to process and handle alerts from the scale  9  indicating an overweight condition indicating a weight in excess of 1,500 lbs. In this regard, should the configuration data  18  or firmware  19  later be changed, overweight alarms may be sent at different weights than expect by the industrial controller  2 , which can cause the industrial control system  1  to function improperly. As such, prior art systems require configuration data  18  or firmware  19  to be matched to that expected by the industrial controller  2 , else the industrial controller  2  will refuse to communicate with the device  12   
   As such, when a replacement device  12  is required, the programmer must identify the individual programmable data  20  of the original device  12  being replaced and, if not included in the replacement device  12 , reconfigure the replacement device  12  to include that programmable data  20 . This can be a particularly arduous process especially if the programmable data  20  was not previously stored elsewhere or if the necessary programmable data  20  is outdated and not widely available. Furthermore, this can be a particularly costly process due to the expense of a programmer as well as any down time caused by the module requiring replacement. 
   Therefore, it would be desirable to have a system and method for maintaining individual or localized programmable data of each module in an industrial control system. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention overcomes the aforementioned drawbacks by providing a system and method for collecting and storing programmable data for each device in an industrial control system. This stored programmable data can then be utilized to automatically match programmable data of a given device in the industrial control system based on the identity of that device. Accordingly, an industrial control system may be effectively and efficiently cloned or replacement devices may be automatically configured to operate in place of the original device. 
   In accordance with one aspect of the invention, an industrial control system is disclosed that includes a central controller having a memory containing programmable data including operating programs for operating the controller, control program for controlling an industrial process, and configuration data configuring values used by the central controller. The central controller is designed to control multiple devices also having memory holding programmable data including operating programs and configuration data. A program is executable by the central controller that causes the central controller to identify memories distributed through the industrial control system having programmable data and collect the programmable data from the memories. Accordingly, the collected programmable data may be used to substantially recreate operation of the industrial control system in a second industrial control system having another central controller substantially identical to the industrial controller and multiple devices connected to the central controller. 
   In accordance with another aspect of the invention, a computer program is disclosed that, when executed by an industrial controller arranged in an industrial control system, causes the industrial controller to request identity information from each of a plurality of modules in the industrial control system. The industrial controller is also caused to compare the identity information of each of the modules to stored identity information. Accordingly, if the identity information of a module in the industrial control system does not match the stored identity information, the industrial controller is caused to automatically send a reconfiguration package to the module to reconfigure the module to match the stored identity information. 
   In accordance with yet another aspect of the invention, a method of automatically maintaining firmware versions in an industrial control system having an industrial controller and a plurality of modules is disclosed. The method includes configuring the industrial controller to automatically request a current firmware version from each of the plurality of modules and configuring the industrial controller to compare the current firmware version of each of the plurality of modules to a list of desired firmware for each of the plurality of modules accessible to the industrial controller. The method also includes configuring the plurality of modules to automatically change the current firmware version to the desired firmware version upon receiving the desired firmware version from the industrial controller. 
   In accordance with still another aspect of the invention, a system for maintaining consistent firmware versions across a plurality of modules in an industrial control system is disclosed. The system includes an industrial controller configured to automatically request a current firmware version of each module in the plurality of modules and a memory module engaged with the industrial controller and having stored thereon a list of desired firmware versions. The industrial controller is configured automatically compare the current firmware version of each module in the plurality of modules and send a desired firmware version to each module in the plurality of modules that has a current firmware version not included on the memory module. 
   Various other features of the present invention will be made apparent from the following detailed description and the drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic diagram of a prior-art industrial control system; 
       FIG. 2  is a schematic diagram of an architectural software layout of the industrial control system; 
       FIG. 3  is a pictorial representation of the interaction of fundamental software components of the industrial control system; 
       FIG. 4  is a schematic diagram of an industrial control system in accordance with the present invention; 
       FIG. 5  is a schematic representation showing the interactions of some of the sub-components of the industrial control system of  FIG. 1 ; and 
       FIG. 6  is a flow chart setting forth the steps of a process for maintaining the programmable data of individual devices within an industrial control system in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to  FIG. 4 , the industrial control system  1  includes a data port  28  configured to facilitate bi-directional access to the removable storage device  30 , preferably including non-volatile memory. That is, as previously described, the industrial controller  2  is configured to utilize the removable storage device  30  as a medium on which to store backups of the program that the industrial control system  1  executes and hardware information, such as module type and module manufacturer information. In this regard, it is contemplated that the industrial controller  2  may be compatible with programs such as ControLogix or ControlFlash, commercial available from Rockwell Automation. 
   Beyond storing operational programs and hardware data, the removable storage device  30  may also store individual programmable data for each module in the industrial control system  1 . Therefore, the industrial controller  2  can access the programmable data stored on the removable storage device  30  and use that information to automatically reconfigure devices  12  within the industrial control system  1 . Alternatively, it is contemplated that the desired programmable data may be stored remotely from the industrial controller  2 , such as on a file server  27  that is accessible by the industrial controller  2  over an intranet or the internet  28 . As will be described, this process may be utilized to facilitate cloning of a given industrial control system  2  or to automatically reconfigure a replacement module that has been inserted into the industrial control system  1  to properly operate as an replacement for the prior device  12 . 
   In particular, as will be described, the industrial controller  2  is configured to automatically identify and maintain the components of the industrial control system  1  based on all three fundamental characteristics for each component in the industrial control system  1 . That is, unlike prior art system such as those described with respect to  FIGS. 1-3 , individual programmable data  20  including configuration data  18  and firmware  19  can be backed up onto the removable storage device  30 . By enabling the programmable data  20  to be included on the removable storage device  30 , as will be described, industrial controllers can be configured to automatically access the programmable data  20  and use this information to automatically reconfigure replacement modules or build a clone of a given industrial control system. In this regard, the process of reconfiguring a replacement device or building a clone of a given industrial control system is not only further facilitated but may even be automated so that human interaction with the industrial control system by a programmer utilizing specialized software may be reduced or, in some cases, even a eliminated. 
   Referring now to  FIG. 5 , the industrial controller  2  is in communication with each device  12   a ,  12   b ,  12   c ,  12   d  in the industrial control system  1 . In this regard, the industrial controller  2  requests identity information from each individual device  12   a ,  12   b ,  12   c ,  12   d  in the industrial control system  1 . When received by the industrial controller  2 , the identity information is processed by a processor  37  to compile a device list  38  that is stored in a system memory  40  of the industrial controller  12 . The device list  38  is a list that includes device identity information  39  and associated in programmable data  41  communicated by each device  12   a ,  12   b ,  12   c ,  12   d.    
   For example, when a given device  12   a  in the industrial control system  1  receives a request from the industrial controller  2  for identity information, the device  12   a  responds by communicating that it is a device having “Identity A” and includes programmable data such as a firmware version of “Version 3”. Upon receipt, the processor  37  integrates the information  39 ,  41  communicated by the device  12   a  into the device list  38 . Therefore, each entry in the device list  38  includes the module identity  39 , such as module type and manufacturer information, and corresponding programmable data  41 , for example, a firmware version. 
   When the removable storage medium  30  is engaged with the industrial controller  2 , the information in the device list  38  is compared against a list  42  of desired information stored on the removable storage medium  30 . In this regard, for example, the industrial controller  2  can immediately identify that the device  12   c  having “Identity A” and firmware “Version 2” is incorrect because the list  42  of desired characteristics stored on the removable storage medium  30  indicates that a device having “Identity A” should have firmware “Version 3”. Therefore, as will be described with respect to  FIG. 5 , the industrial controller  2  can transmit the desired firmware “Version 3” from the removable storage device  30  to device  12   c  to replace incorrect firmware “Version 2” residing thereon. 
   Referring now to  FIG. 6 , a process for supervising and maintaining programmable data across a plurality of devices in an industrial control system  43  begins when the industrial controller is powered  44 . The industrial controller then determines whether it is currently configured to update its software automatically  46 . In this regard, the software of the industrial controller may include an operating program, a control program, and/or configuration data. If so  48 , the industrial controller automatically loads the most recent software currently available  50  and then continues its power-on sequence by loading a communications program  52 . On the other hand, if the industrial controller is not configured to automatically update its software  54 , the update sequence  50  is bypassed and the industrial controller continues by loading the communication program  52 . 
   Once capable of communication with other components within the industrial control system by loading the communications program  52 , the industrial controller requests identity information from each device in the industrial control system  56 . When this information is received for a given device, the industrial controller determines whether that device is approved for updates  58 . This may be done by accessing a list of device identities currently approved for updates or, update approval information may be simply embedded in or associated with the identity information received from the device  56 . If the device is not approved for updates  60 , the industrial controller discontinues the update process for that devices and continues by determining whether other devices are approved for updates  58 . 
   When a device is identified that is approved for updates  62 , the industrial controller then determines whether that devices is set for exact matching of programmable data  64 . If the device is not set for exact matching of programmable data  66 , the industrial controller again discontinues the update process for that devices and continues by determining whether other devices are approved for updates  58  and set for exact matching  64 . 
   Once a device that is set for exact matching of programmable data is identified  68 , the industrial controller determines whether the current device programmable data associated with the identity information transmitted by the device matches a desired programmable data associated with the particular devices identity  70 . 
   It is contemplated that this information may be stored on the removable storage device and randomly accessed by the industrial controller or may be preloaded from the removable storage device as part of the software update  50 . Alternatively, it is contemplated that the desired programmable data may be stored remotely from the industrial controller, such as on a file server that is accessible by the industrial controller over an intranet or the internet. 
   If the current programmable data matches the stored programmable data  72 , no further action with respect to that device is required and the industrial controller simply continues with its iterative and periodic requests for identity information from each device  56 . On the other hand, if the current programmable data does not match the stored programmable data for that particular device, the industrial controller automatically accesses the desired programmable data and sends that programmable data to the particular device  76 . The programmable data may include configuration data as well as firmware or a combination thereof. In either case, the device responds by replacing previous programmable data with the current programmable data sent by the industrial controller  76 . 
   It is contemplated that a reconfiguration package or firmware kit may be pushed from the industrial controller to the device requiring updating. This package may including a self-executing program that, upon receipt at the device, is automatically executed to update the programmable data  76 . Alternatively, an update, for example a firmware update, may be sent to the device and, in response, the device may execute a self-update procedure to install the firmware update, for example, by copying an image of the firmware update into memory. 
   It is contemplated that this firmware supervisor process  78  for checking and maintaining programmable data across the devices of the industrial control system  78  may be iteratively and periodically performed. That is, the industrial controller may be configured to repeatedly work through the loops within the firmware supervisor process  78  to continuously check whether the current programmable data of each device matches the desired programmable data. 
   Accordingly, it is possible to immediately and automatically update the programmable data of a replacement device engaged with the industrial control system without the need for a programmer to utilize a separate computer system to manually perform such a process. In this regard, “headless” updates can be performed. Furthermore, it is contemplated, that this updating and maintenance process may be performed during operation of the industrial control system, whereby replacement devices may be automatically updated without the industrial control system being required to be shut down. Accordingly, the devices may be “hot swappable.” 
   Alternatively, rather than performing the device checking and update process  78  iteratively and periodically, it may be performed upon occurrence of a specific event. For example, the process  78  may be initiated in response to a system power on event, an industrial controller power on event, a device replacement event, a device power on event, a removable memory engagement event, a communications loss event, a memory failure event, expiration of a time limit, or user initiation such as by a pushbutton or the like. 
   Therefore, a system and method for collecting and storing programmable data for each device in an industrial control system is created. This stored programmable data can then be utilized to automatically match programmable data of a given device in the industrial control system based on the identity of that device. Accordingly, an industrial control system may be effectively and efficiently cloned or replacement devices engaged with the industrial control system can be automatically updated without requiring a user or programmer to manually reconfigure the programmable data. 
   The present invention has been described in terms of the preferred embodiments, and it should be appreciated that many equivalents, alternatives, variations, and modifications, aside from those expressly stated, are possible and within the scope of the invention. Therefore, the invention should not be limited to a particular described embodiment.