Patent Document

BACKGROUND OF THE INVENTION 
     The present invention relates to industrial controllers, and in particular, to addressing of industrial controllers employing the network ring topology. 
     Networks used for communication among industrial controllers differ from standard networks in that they must operate to communicate data reliably within predefined time limits. Often this is accomplished by additional communication protocols that reserve network bandwidth and schedule messages to prevent collisions and the like that can introduce unpredictable delay into network communications. 
     Many computer networks also incorporate protocols to repair the network in the event of network node failure. Some protocols can take a relatively long time to reconnect the network (as much as 30 seconds) and thus are unacceptable for industrial control networks where the controlled process cannot be undirected during this period without disastrous consequences. 
     The risk of debilitating network failure in an industrial control can often be avoided using a redundant network topology, for example, where network nodes are connected in a ring with a supervisor. Normally the ring is opened at the supervisor node for all standard data and thus operates in a normal linear topology. The supervisor may send out test “telegram” or “beacon” frames in one direction on the ring which are received back at the supervisor in the other direction to indicate the integrity of the ring. If the ring is broken, such as by a node or media failure, the supervisor joins the ends of the ring to produce once again a continuous linear topology now separated by the failed component. Changes in the mode of operation of the supervisor from “separated” to “joined” may be transmitted to the other nodes using notification frames so that these nodes can rebuild their MAC address routing tables used to associate a port with a destination address. 
     The error detection time of such ring systems can be quite fast, limited principally by the transmission rate of the beacons (every several microseconds). This rate defines the maximum time before which an error is detected and the ring may be reconfigured. As described in U.S. Pat. No. 8,244,838, which reference is hereby incorporated by reference in its entirety, even faster recovery time can be achieved by communicating the topology change in the beacon frame itself, along with monitoring reception or non-reception of beacon frames in ring nodes. 
     While device level ring topologies provide distinct advantages for industrial control systems, addressing knowledge for ring participants is typically required for the control program software to be implemented before the system can be commissioned. This results in inflexibilities in implementing the system. In addition, if an existing industrial control system configured in a ring requires replacement of one or more ring participants, the control program typically also requires modification with respect to addressing for the one or more replacement devices. This can result in increased complexity for replacement in the field which may, in turn, result in increased costly downtime of the system. A need therefore exists to provide an industrial control system having the advantages of a device level ring topology while minimizing the aforementioned drawbacks. 
     SUMMARY OF THE INVENTION 
     The present inventors have recognized that by implementing a ring supervisor to operate as a server for maintaining and allocating addresses for devices in the ring, a device level ring topology may be provided which significantly lessens the need for addressing knowledge prior to commissioning or replacement. The ring supervisor may obtain an ordered list of devices in the ring by sending a data collection frame that passes through each device around the ring with each device appending its preconfigured address information. Accordingly, the ring supervisor may operate to apply the addressing provided by each device, or alternatively, allocate different addresses to each device from a separate pool. 
     As a result, control program software for ring devices can be developed using a general pool of addresses without requiring specific knowledge of the actual addresses for the ring participants to be commissioned in the ring. Also, if a device in the ring requires replacement, the device may be replaced without requiring modification to the control program to provide the address for the replacement device. 
     In accordance with an embodiment, a ring network may comprise a plurality of switching nodes providing Layer 2 functionality to forward data frames between ports, each switching node having at least a first and second port connectable to network media, the switching nodes arranged in a network ring wherein the first and second ports of each switching node connect to different switching nodes of the network ring and wherein at least one of the switching nodes is an active ring supervisor and the other switching nodes are ring devices. The active ring supervisor may executes to: (a) transmit a data collection frame out of one port for traversing the ring, wherein the data collection frame transmits through each device on the ring in an order in which they are connected, and wherein each device provides at least one of its MAC address and its IP address to the active ring supervisor in response to the data collection frame; and (b) maintain a data structure listing each device on the ring, wherein the data structure indicates the order in which each device is connected on the ring, and wherein the data structure indicates the at least one of a MAC address and an IP address for each device. 
     The active ring supervisor may operate as a Dynamic Host Configuration Protocol (DHCP) server and execute to allocate an IP address to each device on the ring. 
     Upon a change of one or more targeted devices in the ring, the active ring supervisor may transmit a second data collection frame and compare the data structure to an updated data structure resulting from the second data collection frame. 
     Following the compare, upon determining a same number of devices in the ring and a same ordering of devices in the ring with only the one or more targeted devices changed to one or more different devices, the active ring supervisor reallocates each IP address from the one or more targeted devices to the one or more different devices. 
     Following the compare, upon determining at least one of a different number of devices in the ring and a different ordering of devices in the ring, the active ring supervisor sends an alert message warning of the change to the user. 
     These and other features and advantages of the invention will become apparent to those skilled in the art from the following detailed description and the accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which: 
         FIG. 1  is a diagram of an industrial control network configured for use in accordance with an embodiment of the invention; 
         FIG. 2A  is a depiction of the fields of a data collection frame for communicating in the ring, and  FIG. 2B  is a depiction of the fields of the data collection frame providing an ordered list of devices and preconfigured address information, each in accordance with an embodiment of the invention; 
         FIG. 3  is a diagram illustrating a ring supervisor allocating addresses to devices in the ring in accordance with an embodiment of the invention; 
         FIG. 4  is a user interface for viewing and configuring addresses in the ring in accordance with an embodiment of the invention; 
         FIG. 5A  is a depiction of a data structure listing each device on the ring in which a device has been replaced,  FIG. 5B  is a depiction of a data structure in which a device has been replaced and devices have been reordered, and  FIG. 5C  is a depiction of a data structure in which a device has been added, each in accordance with an embodiment of the invention; 
         FIG. 6  is a flow chart illustrating a process for initial address assignment in accordance with an embodiment of the invention; and 
         FIG. 7  is a flow chart illustrating a process for address assignment after device replacement in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIG. 1 , an exemplar industrial control network  10  is provided in a device level ring topology similar to the industrial control network described in U.S. Pat. No. 8,244,838, which reference is hereby incorporated by reference in its entirety. The industrial control network  10  may include, for example, a programmable logic controller  12  executing a stored program to provide for real-time control of an industrial process  14 . Real-time control, in this context, means control that is subject to well-defined maximum delay periods between an output signal generated by the programmable logic controller  12  and electrical signal sent to an actuator in the industrial process  14 , and similarly well-defined maximum delay period between the generation of a signal by a sensor in the industrial process  14  and its receipt and processing by the programmable logic controller  12 . 
     Normally the programmable logic controller  12  includes an electronic computer executing a program stored in a non-transient medium providing detailed logic for the necessary control. Often the stored program is generated uniquely for the particular industrial process  14 . 
     The programmable logic controller  12  may communicate with a terminal device  16 , or Human Machine Interface (HMI), that allows for the configuration of the industrial controller by a user, including the generation of the control program and the initialization of its components. The programmable logic controller  12  may also communicate with a network node or ring device  18  (in this example active ring supervisor  18   a ) implementing protocols suitable for Ethernet or Internet Protocol (IP) or other control network protocols. The active ring supervisor  18   a  may be an Ethernet node having a processor  44 , two ports  20  (labeled A and B respectively) and an embedded switching ASIC  45  to switch network traffic between two ports and a processor  44 . In this example, the active ring supervisor  18   a  will provide for layer 2 protocol to implement a full/half duplex IEEE 802.3 Ethernet network. 
     Ports A and B each connect to network media  22 , for example, copper conductors or fiber optic links having a bandwidth of at least 100 Mbps in full duplex mode. The media  22  may connect to other network nodes or ring devices  18   b ,  18   c ,  18   d  and  18   e  each also having a processor  44 , two ports  20  (A and B) and a custom embedded switching ASIC  45  or a commercial embedded switching IC. The other ring devices  18  may also include ring protocol aware switches and/or ring protocol unaware commercial off-the-shelf (“COTS”) managed switches, each with three or more ports with two ports connected to the ring and remaining ports connected to other single port or multi-port network nodes. The ring devices  18   b - e  may communicate with I/O circuits or other control devices providing signals along conductors  24  to and from the industrial process  14  for control thereof. Non-supervisory ring devices  18   b - e  may operate as back up ring supervisors. 
     During normal operation, one node (in this case node  18   a ) will operate as the active ring supervisor  18   a  (also termed active supervisory node) and in this capacity will send various types of frames from each of its ports  20 . 
     The media  22  interconnects the ports  20  of the ring devices  18  to produce a ring topology, that is, one in which by following the media  22  one may arrive successively at each ring device  18  once passing through each of the ports A and B of each of the ring devices  18 . The ring topology represents a physical connection and is independent of whether frames may actually pass through the ports A and B as may be prevented by failure of the media  22  or of one or more ring devices  18 . A ring state may indicate whether the ends of the ring are open at the active ring supervisor  18   a  meaning that frames are not passed between ports A and B (open mode) or the ends of the ring are closed at the active ring supervisor  18   a  allowing frames to pass between ports A and B (closed mode). 
     The active ring supervisor  18   a  may transmit conventional Ethernet data frames carrying data fir the control of the industrial process  14 . These data frames will be directed to particular ring devices  18  through a port A or B determined by an internal routing table constructed according to methods known in the art. 
     When the ring transitions to a normal mode of operation, and the ring is closed, the active ring supervisor  18   a  transmits a “Sign_On” data collection frame  26  out of one port, such as its unblocked port A, for traversing the ring. The data collection frame  26  transmits through each of the ring devices  18   b - e  on the ring in an order in which they are connected. Each of the ring devices  18   b - e  provides its address information, such as in the form of its MAC address, its IP address, or otherwise, to the active ring supervisor in response to the data collection frame, such as in the data collection frame as the frame transmits through the device. The data collection frame  26  eventually reaches back to the active ring supervisor  18   a  as data collection frame  26 ′, such as through its blocked port B. 
     Referring now to  FIG. 2A , a depiction of the fields of the data collection frame  26  for communicating in the ring is provided in accordance with an embodiment of the invention. A first field  28  provides the “Sign_On” command frame which routes the command to each of the ring devices  18   b - e . An optional Cyclic Redundancy Check (CRC) or other error handling field  30  may also be provided for ensuring data integrity for the data collection frame  26 . As each of the ring devices  18   b - e  receive the data collection frame  26 , each ring device  18  may append its preconfigured address information to the data collection frame  26  in the order in which the ring devices  18   b - e  are connected in the ring. Each of the ring devices  18   b - e  may also update the error handling field  30  as it passes the “Sign_On” command flame to the next ring device  18  with its appended data. 
     Referring now to  FIG. 2B , a depiction of the fields of the data collection frame  26 ′ which provides an ordered list of ring devices  18  and corresponding preconfigured address information is provided in accordance with an embodiment of the invention. The data collection frame  26 ′, as it reaches back to the active ring supervisor  18   a , now includes ring device address fields  32 ,  34 ,  36  and  38  for each of the ring devices  18   b ,  18   c ,  18   d  and  18   e , respectively. These address fields  32 ,  34 ,  36  and  38  are also provided in an order in which the data collection frame  26 ′ passed through each of the ring devices  18   b - e . These address fields  32 ,  34 ,  36  and  38  indicate for each respective network node a specific MAC address, a specific IP address, and/or any other specific networking or addressing parameters important for each respective ring device  18 . If a device does not have an IP address assigned yet, the device will append a zero for its IP address. In addition, the error handling field  30 ′ provides updated error handling for the data collection frame  26 ′ along the way. 
     Referring now to  FIG. 3 , a diagram illustrating a ring supervisor allocating addresses to devices in the ring is provided in accordance with an embodiment of the invention. The active ring supervisor  18   a  maintains a data structure  50  listing each device on the ring. The data structure  50  indicates an order  52  in which each device is connected on the ring. The data structure  50  also indicates a specific MAC address  54 , a specific IP address  56 , and/or any other specific networking or addressing parameters important for each respective ring device  18 . The active ring supervisor  18   a  may essentially derive the data structure  50  from the data collection frame  26 ′. The data structure  50 , serving as an ordered participant list, may be available through a device level ring object interface of the active ring supervisor  18   a . Accordingly, the data structure  50  can be used to assign IP addresses to the ring devices  18   b - e  or to learn assigned IP addresses of the ring devices  18   b - e.    
     In an embodiment, to implement a dynamic address assignment scheme, the active ring supervisor  18   a  allocates an IP address to each device on the ring. The active ring supervisor  18   a  may reference a plurality of predetermined IP addresses  60  which may be provided, for example, by a user via the terminal device  16 , and which may comprise one or more sequential ranges of predetermined IP addresses. The active ring supervisor  18   a  may then, in turn, operate as a Dynamic Host Configuration Protocol (DHCP) server and allocate an IP address from the predetermined IP addresses  60  to each of the ring devices  18   b - e . The active ring supervisor  18   a  may allocate IP addresses to the ring devices  18   b - e  immediately or after a particular ring device  18  makes a request. Accordingly, the active ring supervisor  18   a  may use the data structure  50  for mapping devices on the ring to allocated IP addresses  62  to effectively produce a reference table  64  for the dynamic address assignment. In embodiments, the reference table  64  may simply be an extension of the data structure  50 , or may be a separate data structure altogether. 
     In a preferred embodiment, the active ring supervisor  18   a  waits until the ring is closed and the data collection frame  26 ′ is updated and complete before assigning IP addresses to the ring devices  18   b - e . Any address requests received during the ring fault period and while waiting for the data collection frame  26 ′ to update and complete may be dropped by the active ring supervisor  18   a.    
     In another embodiment, to implement a manual or static address assignment scheme, the ring devices  18   b - e  may be manually configured with an address, such as through a static IP address switch mechanism provided by the ring device. Accordingly, the active ring supervisor  18   a  may simply apply the data structure  50 , derived from the data collection frame  26 ′, as a final mapping for the ring devices  18   b - e.    
     Referring now to  FIG. 4 , a user interface  70  for viewing and configuring addresses in the ring is provided in accordance with an embodiment of the invention. The user interface  70  may appear on the terminal device  16  to effectively illustrate aspects of the data structure  50 , such as in the form of an array  72 . A user may press a “populate” button  74  on the user interface  70  to retrieve and populate an ordered list of MAC addresses, IP addresses and/or other addressing or networking parameters from the data structure  50  to the user interface  70 . The user may then add, modify or delete information in the array  72  as may be needed to effect useful operation of the control network. For example, the user can insert new entries in various orders via a “+” button  76  corresponding by row in the array  72 , or delete existing entries via an “x” button  78  also corresponding by row in the array  72 . After verifying correctness of the information, the user can push a “learn” button  80  on the user interface  70  to apply the information in the array  72  as the reference table. In addition, the user can subsequently push a “refresh” button  82  for retrieving and populating the array  72  with more recent information as desirable. 
     During operation, one or more ring devices may be targeted for a change (or update), such as for upgrading a device, providing maintenance, addressing a malfunction, and so forth. Upon a change of one or more targeted ring devices  18 , the active ring supervisor  18   a  may transmit and receive a second data collection frame  26 ″ and compare the data structure  50  to an updated data structure  50 ′ resulting from second data collection frame  26 ″. For example, referring now to  FIGS. 3 and 5A , a depiction of an updated data structure  50 ′ is provided which lists each of the ring device  18 . In comparing the data structure  50  to the updated data structure  50 ′, the active ring supervisor  18   a  may determine that a same number of devices are in the ring and that a same ordering of devices are in the ring with only one targeted device  90  changed to a different device  92 . Accordingly, the active ring supervisor  18   a  may reallocate the IP address  94 , previously mapped to the targeted device  90 , to the different devices  92 . 
     In other words, if the data structure  50  and the updated data structure  50 ′ are of the same size, with exactly “x” number of old devices having been removed and replaced with “x” number of new devices in same order, the active ring supervisor  18   a  can update the reference table  64  with new MAC addresses from the new participant list. When a DHCP request comes from the different device  92 , the active ring supervisor  18   a  can reallocate the IP address to the new device. 
     However, if the data structure  50  and the updated data structure  50 ′ are not of the same size, such as “x” number of old devices having been removed and replaced with “y” number of new devices, or if the data structure  50  and the updated data structure  50 ′ are of the same size with “x” old devices replaced with “x” new devices but in different order, the active ring supervisor  18   a  may instead send an alert message warning the user, such as through the terminal device  16 , that multiple devices have been replaced and/or reordered, and that the reference table  64  is incorrect. As such, IP addresses are not reallocated. 
     For example, referring now to  FIGS. 3 and 5B , a depiction of an updated data structure  50 ″ is provided which lists each of the ring device  18 . In comparing the data structure  50  to the updated data structure  50 ″, the active ring supervisor  18   a  may determine that a same number of devices are in the ring, but that some ring devices  95  and  96  have been reordered. Consequently, an alert message may be sent warning the user, and IP addresses are not reallocated. 
     In another example, referring now to  FIGS. 3 and 5C , a depiction of an updated data structure  50 ′ is provided which lists each of the ring device  18 . In comparing the data structure  50  to the updated data structure  50 ′″, the active ring supervisor  18   a  may determine that a different number of devices are in the ring, such as ring devices  98 . Consequently, an alert message may be sent warning the user and without IP addresses being reallocated. 
     Referring now to  FIG. 6 , a flow chart illustrating an initial address assignment is provided at process  110  in accordance with an embodiment of the invention. In process block  112 , an active ring supervisor is determined and the ring transitions to a normal, or closed, ring mode of operation. Next, in process block  114 , the active ring supervisor sends out a Sign_On frame, data collection frame, which travels through the ring devices in order and collects participant&#39;s list information in the form of MAC and IP addresses of each device. 
     Next, in decision block  116 , it is optionally determined if the Sign_On frame with the ordered participant information reaches back to the active ring supervisor within a predetermined amount of time. This essentially accounts for slower ring devices which might not have powered up or changed its internal state to a closed ring mode in time. If the Sign_On frame reaches back to the active ring supervisor within a predetermined amount of time, such as within 1 minute, in process block  118 , a data structure listing each device on the ring in the order in which each device is connected, and indicating the MAC and IP addresses and/or other information for each device, is prepared. Otherwise, the decision block  116  returns to the process block  114  to send a subsequent Sign_On frame, in which case the earlier Sign_On frame is disregarded. 
     Next, in decision block  120 , it is determined if a dynamic assignment scheme has been selected. If so, in process block  122 , the active ring supervisor may reference a table or pool of predetermined IP addresses for allocating to ring devices in generating a reference table. Next in process block  124 , the active ring supervisor may receive an IP address request from a ring device, such as a DHCP request, and in process block  126 , the active ring supervisor may allocate an IP address to ring device accordingly. Alternatively, in process block  122 , the active ring supervisor may immediately allocate an IP address to ring devices. Next, process block  126 , the active ring supervisor may communicate allocated IP addresses to ring devices. 
     In decision block  120  if is determined that a dynamic assignment scheme has been not been selected, such as if static assignment has been selected instead, the process  110  continues to process block  128 . Here, the active ring supervisor may maintain and apply the data structure for mapping devices on the ring to the static IP addresses for the devices. In other words, preconfigured addresses are used. If preconfigured addresses are unavailable the active ring supervisor may send an alert message. 
     Referring now to  FIG. 7 , a flow chart illustrating address assignment after device replacement is provided, at process  140  in accordance with an embodiment of the invention. In process block  142 , upon a change of one or more targeted devices in the ring, the active ring supervisor transmits a second, subsequent Sign_On frame, or data collection frame, which travels through the ring devices in order and collects participant&#39;s list information in the form of MAC and IP addresses of each device. 
     Next, similar to decision block  116 , in decision block  144 , it is optionally determined if the Sign_On frame with the ordered participant information reaches back to the active ring supervisor within a predetermined amount of time. If the Sign_On frame reaches back to the active ring supervisor within a predetermined amount of time, such as within 1 minute, in process block  146 , a second data structure listing each device on the ring in the order in which each device is connected, and indicating the MAC and IP addresses and/or other information for each device, is prepared. Otherwise, the decision block  144  returns to the process block  142  to send a subsequent Sign_On frame and earlier Sign_On frame is disregarded. 
     Next, in process block  148 , the second data structure is compared to the earlier data structure. Next, in decision block  150 , it is determined if a same number of devices are on the ring presently as compared to before. If there are a different number of devices on the ring, in process block  152  the active ring supervisor sends an alert message warning of the change, and previous IP address allocations, such as those provided in the reference table, are not reallocated. However, if there are a same number of device on the ring, the process  140  continues to decision block  154 . 
     In decision block  154 , it is determined if there is a same ordering of devices in the ring presently as compared to before with only the one or more targeted devices changed to one or more different devices. If the ordering has changed, in process block  152  the active ring supervisor sends an alert message warning of the change and previous address allocations, such as those provided in the reference table, are not reallocated. However, if the order has not changed, the process  140  continues to process block  156  in which the active ring supervisor reallocates IP addresses from the one or more targeted devices to the one or more different devices thereby updating the reference table. Decision blocks  150  and  154  may be completed in either order. 
     The technical effect of the invention is to reduce complexity for commissioning and/or replacing devices while retaining the advantages of a network ring topology. 
     Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. For example, the terms “first,” “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context. 
     When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     References to “a microprocessor” and “a processor” or “the microprocessor” and “the processor,” can be understood to include one or more microprocessors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices. Furthermore, references to memory, unless otherwise specified, can include one or more processor-readable and accessible memory elements and/or components that can be internal to the processor-controlled device, external to the processor-controlled device, and can be accessed via a wired or wireless network. 
     It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications, are hereby incorporated herein by reference in their entireties.

Technology Category: 5