Abstract:
A wireless communication system for use in a process environment uses mesh and possibly a combination of mesh and point-to-point communications to produce a wireless communication network that can be easily set up, configured, changed and monitored, thereby making a wireless communication network that is less expensive, and more robust and reliable. The wireless communication system allows virtual communication paths to be established and used within the process control system in a manner that is independent of the manner in which the wireless signals are sent between different wireless transmitting and receiving devices within the process plant, to thereby operate in a manner that is independent of the specific messages or virtual communication paths within the process plant. Still further, communication analysis tools are provided to enable a user or operator to view the operation of the wireless communication network to thereby analyze the ongoing operation of the wireless communications within the wireless communication network.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 11/156,215, filed Jun. 17, 2005 and entitled “Wireless Architecture and Support for Process Control Systems” which is a continuation-in-part of pending U.S. application Ser. No. 10/464,087, filed Jun. 18, 2003 and entitled “Self-Configuring Communication Networks for use with Process Control Systems” (which is hereby expressly incorporated by reference herein). 
     
    
     FIELD OF TECHNOLOGY 
       [0002]    Methods and apparatuses are disclosed for providing wireless communications within a distributed process control system which establish and maintain consistent wireless communication connections between different remote devices and a base computer in a process control system. 
       BACKGROUND 
       [0003]    Process control systems are widely used in factories and/or plants in which products are manufactured or processes are controlled (e.g., chemical manufacturing, power plant control, etc.). Process control systems are also used in the harvesting of natural resources such as, for example, oil and gas drilling and handling processes, etc. In fact, virtually any manufacturing process, resource harvesting process, etc. can be automated through the application of one or more process control systems. It is believed the process control systems will eventually be used more extensively in agriculture as well. 
         [0004]    The manner in which process control systems are implemented has evolved over the years. Older generations of process control systems were typically implemented using dedicated, centralized hardware and hard-wired connections. 
         [0005]    However, modern process control systems are typically implemented using a highly distributed network of workstations, intelligent controllers, smart field devices, and the like, some or all of which may perform a portion of an overall process control strategy or scheme. In particular, most modern process control systems include smart field devices and other process control components that are communicatively coupled to each other and/or to one or more process controllers via one or more digital data buses. In addition to smart field devices, modern process control systems may also include analog field devices such as, for example, 4-20 milliamp (mA) devices, 0-10 volts direct current (VDC) devices, etc., which are typically directly coupled to controllers as opposed to a shared digital data bus or the like. 
         [0006]    In a typical industrial or process plant, a distributed control system (DCS) is used to control many of the industrial processes performed at the plant. The plant may have a centralized control room having a computer system with user input/output (I/O), a disc I/O, and other peripherals known in the computing art with one or more process controllers and process I/O subsystems communicatively connected to the centralized control room. Additionally, one or more field devices are typically connected to the I/O subsystems and to the process controllers to implement control and measurement activities within the plant. While the process I/O subsystem may include a plurality of I/O ports connected to the various field devices throughout the plant, the field devices may include various types of analytical equipment, silicon pressure sensors, capacitive pressure sensors, resistive temperature detectors, thermocouples, strain gauges, limit switches, on/off switches, flow transmitters, pressure transmitters, capacitance level switches, weigh scales, transducers, valve positioners, valve controllers, actuators, solenoids, indicator lights or any other device typically used in process plants. 
         [0007]    As used herein, the term “field device” encompasses these devices, as well as any other device that performs a function in a control system. In any event, field devices may include, for example, input devices (e.g., devices such as sensors that provide status signals that are indicative of process control parameters such as, for example, temperature, pressure, flow rate, etc.), as well as control operators or actuators that perform actions in response to commands received from controllers and/or other field devices. 
         [0008]    Traditionally, analog field devices have been connected to the controller by two-wire twisted pair current loops, with each device connected to the controller by a single two-wire twisted pair. Analog field devices are capable of responding to or transmitting an electrical signal within a specified range. In a typical configuration, it is common to have a voltage differential of approximately 20-25 volts between the two wires of the pair and a current of 4-20 mA running through the loop. An analog field device that transmits a signal to the control room modulates the current running through the current loop, with the current being proportional to the sensed process variable. 
         [0009]    An analog field device that performs an action under control of the control room is controlled by the magnitude of the current through the loop, which current is modulated by the I/O port of the process I/O system, which in turn is controlled by the controller. Traditional two-wire analog devices having active electronics can also receive up to 40 milliwatts of power from the loop. Analog field devices requiring more power are typically connected to the controller using four wires, with two of the wires delivering power to the device. Such devices are known in the art as four-wire devices and are not power limited, as typically are two-wire devices. 
         [0010]    A discrete field device can transmit or respond to a binary signal. Typically, discrete field devices operate with a 24 volt signal (either AC or DC), a 110 or 240 volt AC signal, or a 5 volt DC signal. Of course, a discrete device may be designed to operate in accordance with any electrical specification required by a particular control environment. A discrete input field device is simply a switch which either makes or breaks the connection to the controller, while a discrete output field device will take an action based on the presence or absence of a signal from the controller. 
         [0011]    Historically, most traditional field devices have had either a single input or a single output that was directly related to the primary function performed by the field device. For example, the only function implemented by a traditional analog resistive temperature sensor is to transmit a temperature by modulating the current flowing through the two-wire twisted pair, while the only function implemented by a traditional analog valve positioner is to position a valve somewhere between a fully open and a fully closed position based on the magnitude of the current flowing through the two-wire twisted pair. 
         [0012]    More recently, field devices that are part of hybrid systems become available that superimpose digital data on the current loop used to transmit analog signals. One such hybrid system is known in the control art as the Highway Addressable Remote Transducer (HART) protocol. The HART system uses the magnitude of the current in the current loop to send an analog control signal or to receive a sensed process variable (as in the traditional system), but also superimposes a digital carrier signal upon the current loop signal. The HART protocol makes use of the Bell 202 Frequency Shift Keying (FSK) standard to superimpose the digital signals at a low level on top of the 4-20 mA analog signals. This enables two-way field communication to take place and makes it possible for additional information beyond just the normal process variable to be communicated to/from a smart field instrument. The HART protocol communicates at 1200 bps without interrupting the 4-20 mA signal and allows a host application (master) to get two or more digital updates per second from a field device. As the digital FSK signal is phase continuous, there is no interference with the 4-20 mA signal. 
         [0013]    The FSK signal is relatively slow and can therefore provide updates of a secondary process variable or other parameter at a rate of approximately 2-3 updates per second. Generally, the digital carrier signal is used to send secondary and diagnostic information and is not used to realize the primary control function of the field device. Examples of information provided over the digital carrier signal include secondary process variables, diagnostic information (including sensor diagnostics, device diagnostics, wiring diagnostics, and process diagnostics), operating temperatures, a sensor temperature, calibration information, device ID numbers, materials of construction, configuration or programming information, etc. Accordingly, a single hybrid field device may have a variety of input and output variables and may implement a variety of functions. 
         [0014]    More recently, a newer control protocol has been defined by the Instrument Society of America (ISA). The new protocol is generally referred to as Fieldbus, and is specifically referred to as SP50, which is as acronym for Standards and Practice Subcommittee 50. The Fieldbus protocol defines two subprotocols. An H1 Fieldbus network transmits data at a rate up to 31.25 kilobits per second and provides power to field devices coupled to the network. An H2 Fieldbus network transmits data at a rate up to 2.5 megabits per second, does not provide power to field devices connected to the network, and is provided with redundant transmission media. Fieldbus is a nonproprietary open standard and is now prevalent in the industry and, as such, many types of Fieldbus devices have been developed and are in use in process plants. Because Fieldbus devices are used in addition to other types of field devices, such as HART and 4-20 mA devices, with a separate support and I/O communication structure associated with each of these different types of devices. 
         [0015]    Newer smart field devices, which are typically all digital in nature, have maintenance modes and enhanced functions that are not accessible from or compatible with older control systems. Even when all components of a distributed control system adhere to the same standard (such as the Fieldbus standard), one manufacturer&#39;s control equipment may not be able to access the secondary functions or secondary information provided by another manufacturer&#39;s field devices. 
         [0016]    Thus, one particularly important aspect of process control system design involves the manner in which field devices are communicatively coupled to each other, to controllers and to other systems or devices within a process control system or a process plant. In general, the various communication channels, links and paths that enable the field devices to function within the process control system are commonly collectively referred to as an input/output (I/O) communication network. 
         [0017]    The communication network topology and physical connections or paths used to implement an I/O communication network can have a substantial impact on the robustness or integrity of field device communications, particularly when the I/O communications network is subjected to environmental factors or conditions associated with the process control system. For example, many industrial control applications subject field devices and their associated I/O communication networks to harsh physical environments (e.g., high, low or highly variable ambient temperatures, vibrations, corrosive gases or liquids, etc.), difficult electrical environments (e.g., high noise environments, poor power quality, transient voltages, etc.), etc. In any case, environmental factors can compromise the integrity of communications between one or more field devices, controllers, etc. In some cases, such compromised communications could prevent the process control system from carrying out its control routines in an effective or proper manner, which could result in reduced process control system efficiency and/or profitability, excessive wear or damage to equipment, dangerous conditions that could damage or destroy equipment, building structures, the environment and/or people, etc. 
         [0018]    In order to minimize the effect of environmental factors and to assure a consistent communication path, I/O communication networks used in process control systems have historically been hardwired networks, with the wires being encased in environmentally protected materials such as insulation, shielding and conduit. Also, the field devices within these process control systems have typically been communicatively coupled to controllers, workstations, and other process control system components using a hardwired hierarchical topology in which non-smart field devices are directly coupled to controllers using analog interfaces such as, for example, 4-20 mA, 0-10 VDC, etc. hardwired interfaces or I/O boards. Smart field devices, such as Fieldbus devices, are also coupled via hardwired digital data busses, which are coupled to controllers via smart field device interfaces. 
         [0019]    While hardwired I/O communication networks can initially provide a robust I/O communication network, their robustness can be seriously degraded over time as a result of environmental stresses (e.g., corrosive gases or liquids, vibration, humidity, etc.). For example, contact resistances associated with the I/O communication network wiring may increase substantially due to corrosion, oxidation and the like. In addition, wiring insulation and/or shielding may degrade or fail, thereby creating a condition under which environmental electrical interference or noise can more easily corrupt the signals transmitted via the I/O communication network wires. In some cases, failed insulation may result in a short circuit condition that results in a complete failure of the associated I/O communication wires. 
         [0020]    Additionally, hardwired I/O communication networks are typically expensive to install, particularly in cases where the I/O communication network is associated with a large industrial plant or facility that is distributed over a relatively large geographic area, for example, an oil refinery or chemical plant that consumes several acres of land. In many instances, the wiring associated with the I/O communication network must span long distances and/or go through, under or around many structures (e.g., walls, buildings, equipment, etc.) Such long wiring runs typically involve substantial amounts of labor, material and expense. Further, such long wiring runs are especially susceptible to signal degradation due to wiring impedances and coupled electrical interference, both of which can result in unreliable communications. 
         [0021]    Moreover, such hardwired I/O communication networks are generally difficult to reconfigure when modifications or updates are needed. Adding a new field device typically requires the installation of wires between the new field device and a controller. Retrofitting a process plant in this manner may be very difficult and expensive due to the long wiring runs and space constraints that are often found in older process control plants and/or systems. High wire counts within conduits, equipment and/or structures interposing along available wiring paths, etc., may significantly increase the difficulty associated with retrofitting or adding field devices to an existing system. Exchanging an existing field device with a new device having different field wiring requirements may present the same difficulties in the case where more and/or different wires have to be installed to accommodate the new device. Such modifications may often result in significant plant downtime. 
         [0022]    It has been suggested to use wireless I/O communication networks to alleviate some of the difficulties associated with hardwired I/O networks. For example, Tapperson et al., U.S. patent application Ser. No. 09/805,124 discloses a system which provides wireless communications between controllers and field devices to augment or supplement the use of hardwired communications. However, most, if not all, wireless I/O communication networks actually implemented within process plants today are implemented using relatively expensive hardware devices (e.g., wireless enabled routers, hubs, switches, etc.), most of which consume a relatively large amount of power. Further, intermittent interferences, such as the passing of trucks, trains, environmental or whether related conditions, etc., make wireless communication networks unreliable and therefore problematic. 
         [0023]    In addition, known wireless I/O communication networks, including the hardware and software associated therewith, generally use point-to-point communication paths that are carefully selected during installation and fixed during subsequent operation of the system. Establishing fixed communication paths within these wireless I/O communication networks typically involves the use of one or more experts to perform an expensive site survey that enables the experts to determine the types and/or locations of the transceivers and other communication equipment. Further, once the fixed point-to-point communication paths have been selected via the site survey results, one or more of the experts must then configure equipment, tune antennas, etc. While the point-to-point paths are generally selected to insure adequate wireless communications, changes within the plant, such as the removal or addition of equipment, walls, or other structures may make the initially selected paths less reliable, leading to unreliable wireless communications. 
         [0024]    While wireless I/O communication networks can, for example, alleviate the long term robustness issues associated with hardwired communication paths, these wireless I/O communication networks are relatively inflexible and are considered by most in the process control industry to be too unreliable to perform important or necessary process control functions. For example, there is currently no easy manner of telling when a wireless communication is no longer functioning properly, or has degraded to the point that communications over the wireless link are likely to be unreliable or to cease altogether. As a result, current process control operators have very little faith in wireless communication networks when implemented for important and necessary process control functions. 
         [0025]    Thus, due to the costs associated with installing a wireless I/O communication network (e.g., site surveys, expert configuration, etc.), and the relative little amount of faith that current process control system operators have in wireless communications, wireless I/O communication networks are often cost prohibitive for what they provide, particularly for relatively large process control systems such as those typically used in industrial applications. 
       SUMMARY OF THE DISCLOSURE 
       [0026]    A wireless communication architecture for use in a process control system is disclosed which includes the use of mesh and possibly a combination of mesh and point-to-point communications to produce a more robust wireless communication network that can be easily set up, configured, changed and monitored, to thereby make the wireless communication network more robust, less expensive and more reliable. The wireless communication architecture is implemented in a manner that is independent of the specific messages or virtual communication paths within the process plant and, in fact, the wireless communication network is implemented to allow virtual communication paths to be established and used within the process control system in a manner that is independent of the manner in which the wireless signals are sent between different wireless transmitting and receiving devices within the process plant. 
         [0027]    In a refinement, one or more environmental nodes are used to control and optimize the operation of the wireless communication network. The environmental node(s) are linked to field “environmental” devices providing signals indicative of one or more environmental factors such as temperature, barometric pressure, humidity, rainfall and radio frequency (RF) ambient noise, amongst other environmental factors that could alter the operation of the network. 
         [0028]    In another refinement, the network includes a main controller linked to a wireless card. The wireless card is in communication with a repeater node which, in turn, is in communication with a field node. The field node is linked to a plurality of field devices. In another refinement, the repeater node is eliminated. In another refinement, an environmental node and environmental detection devices as discussed above are incorporated with or without one or more repeater nodes. In a further refinement, the field and environmental nodes include a plurality of ports for communication with the field devices. 
         [0029]    In a refinement, the wireless communication network is set up to transmit HART communication signals between different devices within the process plant to thereby enable a robust wireless communication network to be used in a process plant or any other environment having HART capable devices. 
         [0030]    In an embodiment, a process control wireless communication network is disclosed which comprises a base node, a field node, an environmental node and a host. The base node is communicatively coupled to the host. The base, field and environmental nodes each comprising a wireless conversion unit and a wireless transceiver. The wireless transceivers of the base, the field and environmental nodes effect wireless communication among the base, field and environmental nodes. The field node comprises at least one field device providing process controlled data. The environmental node comprises at least one field device providing data regarding environmental factors that may effect operation of the wireless communication network. 
         [0031]    In a refinement, the network also comprises a repeater node comprising a wireless conversion unit in a wireless transceiver. The repeater node effects wireless communications amongst the base, field and environmental node. 
         [0032]    In another refinement, the environmental node comprises a plurality of field devices, each providing data selected from the group consisting of temperature, barometric pressure, humidity, rainfall and radio frequency ambient noise. 
         [0033]    In another refinement, at least some of the field devices are HART protocol devices. In another refinement, at least some of the field devices are FIELDBUS™ protocol devices. 
         [0034]    In another refinement, the network comprises a plurality of environmental nodes strategically placed about a process area for communicating environmental data for different locations within the process area. 
         [0035]    In a refinement, the base, environmental and field nodes form a mesh communications network, providing multiple communication pathway options between any two wireless nodes. In another refinement, the base, environmental and field nodes form a point-to-point communications network. In yet another refinement, the network comprises a switch device to convert the base, environmental and field nodes from a mesh communications network to a point-to-point communications network and vice versa. 
         [0036]    Communication tools are also disclosed to enable an operator to view a graphic of the wireless communication system to easily determine the actual wireless communication paths established within a process plant, to determine the strength of any particular path and to determine or view the ability of signals to propagate through the wireless communication network from a sender to a receiver to thereby enable a user or operator to assess the overall operational capabilities of the wireless communication network. 
         [0037]    In a refinement, the communication tools include one or more of graphical topology maps illustrating connectivity between nodes, tabular presentations showing the connectivity matrix and hop counts and actual maps showing location and connectivity of the hardware devices. The monitor that illustrates wireless communications between the base, field and environmental nodes of the network may be associated with the base node or the host. In another refinement, the topology screen display also illustrates structural features of the process area or environment in which the base, field and environmental nodes are disposed. In another refinement, the host is programmed to provide a tabular screen display listing hop counts for communications between the various nodes of the network. 
         [0038]    In another refinement, the wireless communication network is configured to transmit Fieldbus communication signals between different devices within the process plant to thereby enable a robust wireless communication network to be used in a process plant or environment having Fieldbus capable devices in combination with or instead of HART capable devices. 
         [0039]    In a refinement, a method for controlling a process is disclosed which comprises receiving field data from at least one field device, transmitting the field data wirelessly from a field node to a base node, converting the field data to a different protocol, transmitting the field data of the different protocol to a routing node, determining at the routing node an object device for receiving the field data of the different protocol, sending the field data of the different protocol to the object device. 
         [0040]    In another refinement, a method for monitoring a wireless process control network is disclosed which comprises receiving environmental data from one or more environmental field devices of an environmental node, wirelessly transmitting the environmental data to a base node, transmitting the environmental data to a host, interpreting the environmental data at the hose, sending a command from the host to the base node to adjust at least one operating perimeter of the wireless network based upon the environmental data, transmitting the command from the base node to at least one field node comprising at least one field device for executing said command. 
         [0041]    Other advantages and features will be come apparent upon reading the following detailed description and independent claims, an upon reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0042]    For more complete understanding of this disclosure, reference should not be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples. In the drawings: 
           [0043]      FIG. 1  is a combined block and schematic diagram of a conventional hardwired distributed control system; 
           [0044]      FIG. 2  is a combined block and schematic diagram of a wireless communication network within a portion of a process environment designed in accordance with this disclosure; 
           [0045]      FIG. 3  is a diagram of a wireless communication network within a process environment illustrating both mesh and point-to-point wireless communications; 
           [0046]      FIG. 4  is a block diagram of a mesh and point-to-point enabled communication device that may be used to switch between mesh and point-to-point communications within the communication network of  FIG. 3 . 
           [0047]      FIG. 5  is an example of a geometric topology screen display created by a wireless network analysis tool illustrating the wireless communications between different devices within the wireless communication system designed in accordance with this disclosure; 
           [0048]      FIG. 6  is an example screen display presented in tabular form and created by a wireless network analysis tool illustrating the number of hops or the hop count between each of the wireless communication devices within a disclosed wireless communication system; 
           [0049]      FIG. 7  is an example of a topology screen display created by a disclosed wireless network analysis tool illustrating the wireless communications within a graphic of a plant layout to enable an operator or other user to view the specific communications occurring within the wireless communication network and potential physical obstacles presented by the plant layout; 
           [0050]      FIG. 8  is an example screen display created by a disclosed wireless network analysis tool allowing a user or operator to specify the channel routing and identification within the wireless communication network; 
           [0051]      FIG. 9  is an example screen display created by a wireless network analysis tool illustrating graphical displays of information about the wireless communications between different devices within the wireless communication system to enable a user or operator to analyze the operational capabilities and parameters of the wireless communication network; and 
           [0052]      FIG. 10  is a block diagram of a wireless communication device that implements a HART communication protocol wirelessly using a second communication protocol, e.g. the EMBER® protocol. 
       
    
    
       [0053]    It should be understood that the drawings are not to scale and that the embodiments are illustrated by graphic symbol, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details have been omitted which are not necessary for an understanding of the disclosed embodiments and methods or which render other details difficult to perceive. This disclosure is not limited to the particular embodiments illustrated herein. 
       DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0054]      FIG. 1  illustrates a typical hardwired distributed process control system  10  which includes one or more process controllers  12  connected to one or more host workstations or computers  14  (which may be any type of personal computer or workstation). The process controllers  12  are also connected to banks of input/output (I/O) devices  20 ,  22  each of which, in turn, is connected to one or more field devices  25 - 39 . The controllers  12 , which may be, by way of example only, DeltaV™ controllers sold by Fisher-Rosemount Systems, Inc., are communicatively connected to the host computers  14  via, for example, an Ethernet connection  40  or other communication link. Likewise, the controllers  12  are communicatively connected to the field devices  25 - 39  using any desired hardware and software associated with, for example, standard 4-20 ma devices and/or any smart communication protocol such as the Fieldbus or HART protocols. As is generally known, the controllers  12  implement or oversee process control routines stored therein or otherwise associated therewith and communicate with the devices  25 - 39  to control a process in any desired manner. 
         [0055]    The field devices  25 - 39  may be any types of devices, such as sensors, valves, transmitters, positioners, etc. while the I/O cards within the banks  20  and  22  may be any types of I/O devices conforming to any desired communication or controller protocol such as HART, Fieldbus, Profibus, etc. In the embodiment illustrated in  FIG. 1 , the field devices  25 - 27  are standard 4-20 mA devices that communicate over analog lines to the I/O card  22 A. The field devices  28 - 31  are illustrated as HART devices connected to a HART compatible I/O device  20 A. Similarly, the field devices  32 - 39  are smart devices, such as Fieldbus field devices, that communicate over a digital bus  42  or  44  to the I/O cards  20 B or  22 B using, for example, Fieldbus protocol communications. Of course, the field devices  25 - 39  and the banks of I/O cards  20  and  22  could conform to any other desired standard(s) or protocols besides the 4-20 mA, HART or Fieldbus protocols, including any standards or protocols developed in the future. 
         [0056]    Each of the controllers  12  is configured to implement a control strategy using what are commonly referred to as function blocks, wherein each function block is a part (e.g., a subroutine) of an overall control routine and operates in conjunction with other function blocks (via communications called links) to implement process control loops within the process control system  10 . Function blocks typically perform one of an input function, such as that associated with a transmitter, a sensor or other process parameter measurement device, a control function, such as that associated with a control routine that performs PID, fuzzy logic, etc. control, or an output function that controls the operation of some device, such as a valve, to perform some physical function within the process control system  10 . Of course hybrid and other types of function blocks exist. Groups of these function blocks are called modules. Function blocks and modules may be stored in and executed by the controller  12 , which is typically the case when these function blocks are used for, or are associated with standard 4-20 mA devices and some types of smart field devices, or may be stored in and implemented by the field devices themselves, which may be the case with Fieldbus devices. While the control system  10  illustrated in  FIG. 1  is described as using function block control strategy, the control strategy could also be implemented or designed using other conventions, such as ladder logic, sequential flow charts, etc. and using any desired proprietary or non-proprietary programming language. 
         [0057]    As evident from the discussion of  FIG. 1 , the communications between the host workstations  14  and the controllers  12  and between the controllers  12  and the field devices  25 - 39  are implemented with hardwired communication connections, including one or more of HART, Fieldbus and 4-20 mA hardwired communication connections. However, as noted above, it is desirable to replace or augment the hardwired communication connections within the process environment of  FIG. 1  with wireless communications in an manner that is reliable, that is easy to set up and configure, that provides an operator or other user with the ability to analyze or view the functioning capabilities of the wireless network, etc. 
         [0058]      FIG. 2  illustrates a wireless communication network  60  that may be used to provide communications between the different devices illustrated in  FIG. 1  and, in particular, between the controllers  12  (or the associated I/O devices  22 ) of  FIG. 1  and the field devices  25 - 39 , between the controllers  12  and the host workstations  14  or between the host workstations  14  and the field devices  25 - 39  of  FIG. 1 . However, it will be understood that the wireless communication network  60  of  FIG. 2  could be used to provide communications between any other types or sets of devices within a process plant or a process environment. 
         [0059]    The communication network  60  of  FIG. 2  is illustrated as including various communication nodes including one or more base nodes  62 , one or more repeater nodes  64 , one or more environment nodes  66  (illustrated in  FIG. 2  as nodes  66   a  and  66   b ) and one or more field nodes  68  (illustrated in  FIG. 2  as nodes  68   a ,  68   b  and  68   c ). Generally speaking, the nodes of the wireless communication network  60  operate as a mesh type communication network, wherein each node receives a communication, determines if the communication is ultimately destined for that node and, if not, repeats or passes the communication along to any other nodes within communication range. As is known, any node in a mesh network may communicate with any other node in range to forward communications within the network, and a particular communication signal may go through multiple nodes before arriving at the desired destination. 
         [0060]    As illustrated in  FIG. 2 , the base node  62  includes or is communicatively coupled to a work station or a host computer  70  which may be for example any of the hosts or workstations  14  of  FIG. 1 . While the base node  62  is illustrated as being linked to the workstation  70  via a hardwired Ethernet connection  72 , any other communication link may be used instead. As will be described in more detail later, the base node  62  includes a wireless conversion or communication unit  74  and a wireless transceiver  76  to effect wireless communications over the network  60 . In particular, the wireless conversion unit  74  takes signals from the workstation or host  70  and encodes these signals into a wireless communication signal which is then sent over the network  60  via the transmitter portion of the transceiver  76 . Conversely, the wireless conversion unit  74  decodes signals received via the receiver portion of the transceiver  76  to determine if that signal is destined for the base node  62   a  and, if so, further decodes the signal to strip off the wireless encoding to produce the original signal generated by the sender at a different node  64 ,  66  or  68  within the network  60 . 
         [0061]    As will be understood, in a similar manner, each of the other communication nodes including the repeater nodes  64 , the environmental nodes  66  and the field nodes  68  includes a communication unit  74  and a wireless transceiver  76  for encoding, sending and decoding signals sent via the wireless mesh network  60 . While the different types of nodes  64 ,  66 ,  68  within the communication network  60  differ in some important ways, each of these nodes generally operates to receive wireless signals, decode the signal enough to determine if the signal is destined for that node (or a device connected to that node outside of the wireless communication network  60 ), and repeat or retransmit the signal if the signal is not destined for that node and has not previously been transmitted by that node. In this manner, signals are sent from an originating node to all the nodes within wireless communication range, each of the nodes in range which are not the destination node then retransmits the signal to all of the other nodes within range of that node, and the process continues until the signal has propagated to all of the nodes within range of at least one other node. 
         [0062]    However, the repeater node  64  operates to simply repeat signals within the communication network  60  to thereby relay a signal from one node through the repeater node  64  to a second node  62 ,  66  or  68 . Basically, the function of the repeater node  64  is to act as a link between two different nodes to assure that a signal is able to propagate between the two different nodes when these nodes are not or may not be within direct wireless communication range of one another. Because the repeater node  64  is not generally tied to other devices at the node, the repeater node  64  only needs to decode a received signal enough to determine if the signal is a signal that has been previously repeated by the repeater node (that is, a signal that was sent by the repeater node at a previous time and which is simply being received back at the repeater node because of the repeating function of a different node in the communication network  60 ). If the repeater node has not received a particular signal before, the repeater node  64  simply operates to repeat this signal by retransmitting that signal via the transceiver  74  of the repeater node  64 . 
         [0063]    On the other hand, each of the field nodes  68  is generally coupled to one or more devices within the process plant environment and, generally speaking, is coupled to one or more field devices, illustrated as field devices  80 - 85  in  FIG. 2 . The field devices  80 - 85  may be any type of field devices including, for example, four-wire devices, two-wire device, HART devices, Fieldbus devices, 4-20 mA devices, smart or non-smart devices, etc. For the sake of illustration, the field devices  80 - 85  of  FIG. 2  are illustrated as HART field devices, conforming to the HART communication protocol. Of course, the devices  80 - 85  may be any type of device, such as a sensor/transmitter device, a valve, a switch, etc. Additionally, the devices  80 - 85  may be other than traditional field devices such as controllers, I/O devices, work stations, or any other types of devices. 
         [0064]    In any event, the field node  68   a ,  68   b ,  68   c  includes signal lines attached to their respective field devices  80 - 85  to receive communications from and to send communications to the field devices  80 - 85 . Of course, these signal lines may be connected directly to the devices  80 - 85 , in this example, a HART device, or to the standard HART communication lines already attached to the field devices  80 - 85 . If desired, the field devices  80 - 85  may be connected to other devices, such as I/O devices  20 A or  22 A of  FIG. 1 , or to any other desired devices via hardwired communication lines in addition to being connected to the field nodes  68   a ,  68   b ,  68   c . Additionally, as illustrated in  FIG. 2 , any particular field node  68   a ,  68   b ,  68   c  may be connected to a plurality of field devices (as illustrated with respect to the field node  68   c , which is connected to four different field devices  82 - 85 ) and each field node  68   a ,  68   b ,  68   c  operates to relay signals to and from the field devices  80 - 85  to which it is connected. 
         [0065]    In order to assist in the management in the operation of the communication network  60 , the environmental nodes  66  are used. In this case, the environmental nodes  66   a  and  66   b  includes or is communicatively connected to devices or sensors  90 - 92  that measure environmental parameters, such as the humidity, temperature, barometric pressure, rainfall, or any other environmental parameters which may effect the wireless communications occurring within the communication network  60 . As discussed in more detail below, this information may be useful in analyzing and predicting problems within the communication network, as many disruptions in wireless communications are at least partially attributable to environmental conditions. If desired, the environmental sensors  90 - 92  may be any kind of sensor and may include, for example, HART sensors/transmitters, 4-20 mA sensors or on board sensors of any design or configuration. Of course, each environmental node  66   a ,  66   b  may include one or more environmental sensors  90 - 92  and different environmental nodes may include the same or different types or kinds of environmental sensors if so desired. Likewise, if desired, one or more of the nodes  66   a ,  66   b  may include an electromagnetic ambient noise measurement device  93  to measure the ambient electromagnetic noise level, especially at the wavelengths used by the communication network  60  to transmit signals. Of course, if a spectrum other an RF spectrum is used by the communication network  60 , a different type of noise measurement device may be included in one or more of the environmental nodes  66 . Still further, while the environmental nodes  66  of  FIG. 2  are described as including environmental measurement devices or sensors  90 - 93 , any of the other nodes  68  could include those measurement devices so that an analysis tool may be able to determine the environmental conditions at each node when analyzing the operation of the communication network  60 . 
         [0066]    Using the communication system  60  of  FIG. 2 , an application running on the workstation  70  can send packets of data to and receive packets of wireless data from the wireless base card  74  residing in a standard controller  75  at the base node  62 . This controller  75  may be, for example, a DeltaV controller and the communications may be the same as with a standard I/O card via the Ethernet connection to the DeltaV controller. The I/O card in this case includes a wireless base card  74 , though as far as the controller and PC Application goes, it appears as a standard HART I/O card. 
         [0067]    In this case, the wireless card  74  at the base node  62  encodes the data packet for wireless transmission and the transceiver  76  as the base node  62  transmits the signal.  FIG. 2  illustrates that the transmitted signal may go directly to some of the field nodes such as nodes  68   a  and  68   b , but may also propagate to other field nodes, such as nodes  68   c , via the repeater node  64 . In the same manner, signals created at and propagated by the field nodes  68  may go directly to the base node  60  and other field nodes  66  or may be transmitted through other nodes such as the repeater node  64  or another field node before being transmitted to the base node  62 . Thus, the communication path over the wireless network  60  may or may not go through a repeater node  64  and, in any particular case, may go through numerous nodes before arriving at the destination node. If a sending node is in direct communication reach of the base unit  62 , then it will exchange data directly. Whether or not the packets pass through a repeater node  64  is completely transparent to the end user, or even to the card firmware. 
         [0068]    It will be noted that  FIG. 2  is a schematic diagram and the placement of the environmental nodes  66   a ,  66   b  relative to the field nodes  68   a - 68   c  are not intended to be relative to their actual placement in an actual process control area. Rather, the environmental nodes  66   a ,  66   b  (and other environmental nodes not pictured or a single environmental node) are intended to be placed about the process control area in a logical and strategic manner as shown in  FIG. 7 . In other words, environmental nodes  66  should be placed at spaced apart location, such as at opposing ends of large obstacles or pieces of equipment or near roadways where interference from moving vehicles may be present. Also, environmental nodes should be placed both indoors and outdoors if applicable. The network of environmental nodes  66  is intended to be used by the base nodes  62  and host  70  as a means for monitoring the operation of the wireless network  60  and modifying the operation of the network  60  by increasing or decreasing signal strength, gain, frequency etc. 
         [0069]    It will be noted that the field nodes  68  are placed at or near various process stations. The node  68  may be important safety devices or maybe used to monitor and/or control various processes. Further, more than one repeater node  64  may be used and, in fact,  FIG. 2  is but one example as it may be determined that it only single environmental node  66  is necessary, that more than one or no repeater nodes  64  are needed and that fewer than three or more than three field nodes  68  are necessary. 
         [0070]    Turning to  FIGS. 3 and 4 , it is anticipated that the wireless network  60  of  FIG. 2  may need to be switched back and forth between mesh and point-to-point communication modes.  FIG. 3  illustrates a network  100  with a base node  101  in communication with repeater nodes  102   a ,  102   b ,  102   c . The repeater nodes  102   a - 102   c  are, in turn, in communication with a plurality or a cluster of either environmental nodes, field nodes or combination of the two as shown generally at  104 . A point-to-point wireless communication system for  FIG. 3  is shown in solid line while an alternative mesh configuration is shown in solid line. 
         [0071]    Turning to  FIG. 4 , a switch device  105  is shown schematically which may be disposed in the base mode  101  in addition to the wireless and transceiver (not shown). The switch  105  is intended to convert the network  100  from a mesh wireless network as shown by the phantom lines in  FIG. 3  to a point-to-point wireless network as shown by way of example in the solid line of  FIG. 3 . Of course, the point-to-point communications can be configured in any manner and the solid lines shown in  FIG. 3  are but one example. The switch device  105  as shown in  FIG. 4  can include an electronic switch element  106  that shifts the device  105  between a mesh wireless transceiver  76   a  and a point-to-point wireless transceiver  76   b.    
         [0072]    As noted above, the disclosed network  60  includes a base node  62  and host  70  that may be programmed to provide a variety of graphically interfaces that will be useful to the operator. Examples of such graphical interfaces are shown in  FIGS. 5-9 . Turning to  FIG. 5 , a geometric topology screen display  110  is disclosed which illustrates a wireless network between a base node BA and a plurality of other nodes which may be one or more repeater nodes, field nodes and environmental nodes numbered in  FIG. 5  as  03 ,  04 ,  05 ,  06 ,  07 ,  08 ,  09 ,  10  ( 0 A), and  11  ( 0 B). The topology display  110  of  FIG. 5  illustrates a successful communication between two nodes with a solid, dark line, one example of which is the communication between the base node BA and the node  7 . A successful communication in one direction only is illustrated by a lighter line with cross hatches, one example of which is the line between the nodes  03  and  10  ( 0 A). An unsuccessful communication is indicated by a dashed or phantom line, one example of which is the lack of communication illustrated by the dashed line between nodes  05  and  11  ( 0 B).  FIG. 5  also illustrates the “hop count” between nodes. For example, looking at nodes  04  and  07 , the dashed or phantom line between nodes  04  and  07  of  FIG. 5  make it clear that there is no direct wireless communication between nodes  04  and  07  while there is communication between nodes  04  and  05  and one-way communication between nodes  05  and  07 . Thus, for one-way communication between nodes  04  and  07 , there is a hop count of 2 (node  04  to node  05  and node  05  to node  07 ). Alternatively, for two-way communication between nodes  04  and  07 , there is also a hop count of 2 (node  07  to node  03  and node  03  to node  04 ). Obviously, the lower the hop count the better and the more reliable the communication. 
         [0073]    The hop counts for the network shown in  FIG. 5  are shown in tabular form in  FIG. 6 . The nodes labeled  10  and  11  in  FIG. 5  are also indicated as  0 A and  0 B in  FIG. 6 . The base node BA communicates directly with nodes  03  through  0 B and therefore the hop count between the base node BA and any one of  03  through  0 B is one is indicated in the top row of the table shown in  FIG. 6 . Turning to the second row of the table of  FIG. 6 , it will be noted that the hop count between node  03  and any of the other nodes is also 1 as node  3  of  FIG. 5  includes no dashed lines emanating from it. However, turning to the third row of the table of  FIG. 6  and referring to  FIG. 5 , it will be noted that node  04  includes a dashed line extended between node  04  and node  07  and therefore direct communication between node  04  and node  07  is not possible. Thus, to connect from node  04  to node  07 , the communication precedes through node  05  for a hop count of 2. Still further, because there is a light colored cross-hatched line between node  04  and node  09  in  FIG. 5 , direct two-way communication between node  04  and  09  is not possible. Accordingly, for two-way communication between nodes  04  and  09 , the communication must pass through node  08  as indicated in the table of  FIG. 6 . All of the entries that are circled in  FIG. 6  indicate a hop count of 2. 
         [0074]    Turning to  FIG. 7 , a topology map similar to that shown in  FIG. 5  is illustrated as an overlay of a map for an actual process environment. Specifically, each point is the location of 1 of the 9 nodes show in  FIG. 5  and listed in the table of  FIG. 6 .  FIG. 7  provides the operator with an opportunity to view the wireless connectivities within the context of the actual operating environment. Global positioning system reference points are indicated at  111 ,  112  so actual distances between the nodes can be determined. 
         [0075]    Turning to  FIG. 8 , the field devices  80 - 85  and  90 - 93  may appear to the base node  62  or host  70  as a standard HART device. This enables standard applications such as AMS software to run seamlessly on top of the wireless network  60 . To utilize the AMS software, the wireless field nodes  66  and  68  need to know how to route messages. This is accomplished by utilizing a routing map  120  as illustrated in  FIG. 8 . This map  120  is stored in the nonvolatile memory of the base unit  62 , but also could be stored in the memory of the host  70 . The actual routing takes advantage of incorporating a base card that is identical to an 8 channel HART card. The routing tool then maps  8  virtual HART channels to remote field nodes and their channels.  FIG. 8  illustrates a mapping configuration for 8 different devices. Each Field type wireless node may include 4 different HART channels, though the field device will have one unique ID. The actual target channel is embedded in the wireless packet. Each ID for each wireless unit is based on 2 bytes. The first byte is the network number and correlates to an actual radio channel in the wireless interface. The number of the first byte can range from 1 to 12. The second byte is the identification of the node in the network and can range from 1 to 15. When a node is initialized for a first time, its default address is 010F, which mean network  1 , address  15 . The exception to this address scheme is the base unit which always has BA as its first byte, the second byte representing which network the device is in. 
         [0076]    Turning to  FIG. 9 , another graphical presentation  130  for display at the host  70  ( FIG. 1 ) is shown. 4 graphs are shown, one on top of each other with time being plotted on the x-axes. The top graph  131  plots a total hop count for the entire system which, as shown, averages about 72 or slightly less. An increase in the hop count would provide a warning to the operator. The other graphs in  FIG. 9  provide environmental information from the environmental node  66  shown in  FIG. 2 . The graph  132  provides a reading of barometric pressure; the graph  133  provides a reading of humidity; and the graph  134  provides a reading of the general RF background noise within the operating frequency band. Other environmental indications not presented in  FIG. 9  could be temperature and rainfall. 
         [0077]    Turning to  FIG. 10 , it will be noted that many of the devices  80 - 85  shown in  FIG. 2  would be HART field devices, and therefore the field node  68  will be sending a HART signal to either a repeater node  64  or directly to a conversion node  140  which, in the embodiment shown in  FIG. 10 , may be a separate element or may comprise part of the base node  62 . A HART signal may also be sent from an environmental node  66  as shown. The conversion node  140  includes software to convert the HART signal to a different protocol, e.g., the EMBER protocol used with low-power wireless networking software and radio technology. See http://www.ember.com/. Of course, other protocols are available and will be apparent to those skilled in the art. The conversion node  140  converts the HART signal to an EMBER data packet at  141 . The data packet includes an origin indication  142  and a destination indication  143  which is determined by software either in the base node  62  or in the conversion node  140 . The HART message  143  is sandwiched between the origin data  142  and destination data  143 . The signal is then sent to a routing node  145  which determines, from the destination information  143 , which object device  146  to send the data to. The routing node  145  then transmits the data through one or more repeaters  64  and/or field nodes  68  to the object device  146 . One type of software that could be used to convert the field device signal from one protocol (HART) to another protocol is the GTS software sold by Acugen (http://www.acugen.com/jts.htm). 
         [0078]    Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.