WO2000045227A2

WO2000045227A2 - Universal controller with distributed process features

Info

Publication number: WO2000045227A2
Application number: PCT/US2000/002204
Authority: WO
Inventors: Philippe Besnard
Original assignee: Sensormatic Electronics Corporation
Priority date: 1999-01-29
Filing date: 2000-01-28
Publication date: 2000-08-03
Also published as: WO2000045227A3; AU3584700A

Abstract

A distributed processing and control system, comprising: a plurality of distributed, non-dedicated processing units (30); each of the units having a common central processing unit and having a common, distributed software control program stored in the central processing unit; a plurality of dedicated process units (42, 44, 46 and 48), different numbers of which can be coupled to different ones of the central processing units in different combinations to achieve different functions and combinations of functions, the common software control program having a control subprogram for each of the dedicated process units, whereby the distributed process units (30) being customized by the combinations of the dedicated processing units (42, 44, 46 and 48) and operation of the common, distributed software. The distributed process units can form part of a large control network for a work site.

Description

UNIVERSAL CONTROLLER WITH DISTRIBUTED PROCESS FEATURES

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of control systems, and in particular, to a universal controller with distributed process features adapted for operation in a control network.

2. Description of Related Art

Each company that provides controllers and applications develops controller and applications in correlation with their particular needs. The consequence is that these controllers and applications are not flexible because they are each dedicated one to a specific function.

The problem is endemic to all companies. The controllers, which are also referred to as panels in the jargon of access control, and software applications are not compatible with one another. Accordingly, it is impossible to develop integrated solutions.

SUMMARY OF THE INVENTION In accordance with the inventive arrangements, flexible, universal, distributed and non-dedicated controllers are provided, which together with inter-operable methods, are compatible with integrated solutions.

The hardware and software core is common for all functions and applications, including for example, access control, electronic article surveillance (EAS), radio frequency identification (RFID) and video camera control.. Each new application uses the common software and hardware core as a foundation. This can provide an important development cost reduction, for example 60% to 95% of the hardware and software development of a new application, as well as avoiding cost and schedule overruns. This can improve the time to market process by several months due to the utilization of the common core. The common core can provide inter-operability between applications of different sources. The common core and the distributed processing concept can improve the flexibility of the installation and facilitates on-site customization. The competence of the installers and integrators will be enhanced because there need be only one family of controllers to install on site. The skill of the developers can be enhanced by using up-to-date development tools, for example Delphi and C++, by total conformance to existing PC standards, and by a Windows operating system.

An apparatus and method in accordance with the inventive methods, is suitable to be a multi-purpose and a common platform adequate to control one or several industrial applications and realize integrated solutions including security, safety and facility management. The apparatus is a non-dedicated controller which can be connected on a network for large applications or can be used for stand-alone operation. The apparatus allows treatment of information via input and output interfaces and, as a protocol converter, via dedicated controllers. A distributed processing and control system, in accordance with the inventive arrangements, comprises: a plurality of distributed, non-dedicated processing units; each of the units having a common central processing unit and having a common, distributed software control program stored in the central processing unit; a plurality of dedicated process units, different numbers of which can be coupled to different ones of the central processing units in different combinations to achieve different functions and combinations of functions, the common software control program having a control subprogram for each of the dedicated process units, whereby the distributed process units can be assembled from a standard set of components, the distributed processing units being customized by the combinations of the dedicated processing units and operation of the common, distributed software. The distributed process units can form part of a large control network for a work site.

The work site can be at least one of: a manufacturing facility; a warehouse facility; and, a retail merchandising facility.

The distributed processing units can control access of persons into said facility, out of said facility, or both. The distributed processing units can control movement of articles into said facility, out of said facility, or both.

The distributed processing units can control movement of articles and persons into said facility, out of said facility, or both.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a mother board for a distributed processing unit (DPU) in accordance with the inventive arrangements. Figure 2 is an input/output module for use with the mother board shown in Figure 1.

Figures 3 shows the mother board of Figure 1 in a diagrammatic relationship with module process boards.

Figure 4 illustrates software architecture for the DPUs. Figure 5 is a number of flow charts illustrating interactions of the main program and the process subprograms.

Figure 6 is useful for explaining adaptability of the software.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the inventive arrangements, a controller processes all the automated functions or applications that are required in buildings or industrial sites, contrary to the dedicated architecture of traditional controllers or panels. The main characteristic of the new controller is to distribute the processes and the databases inside the buildings and sites, close to the diversified sensors and the actuators. In view of this characteristic, such a controllers or panel is denoted as a distributed processing unit (DPU). Sensors which can communicate with the distributed processing units (DPUs) include, for example: smoke detectors, RFID readers, tag readers, door contacts, access card readers and the like.. Actuators which can be controlled by the DPUs include, for example: electric door locks, lights, sirens and the like. Automated functions or applications which can be implemented by the DPUs include, for example: access control, building management systems, electronic asset surveillance (EAS), sensing and tracking, video switching, audio switching, performance analysis and the like.

The DPUs uses a peer to peer communication and communicate together without need for a host. Due to the architecture and functions, the DPUs are inter-operable between them and can implement co-processed functions between diversified applications. This method of co-processing is denoted autonomation. The DPU is inter-operable with other system applications of other system providers, of the kinds noted above.

The principal features and functions of the DPUs, as presently envisioned, include without limitation: digital and analog data acquisition from sensors; digital and analog outputs to actuators; process control, time processing; incremental and analog counting; internal reflex or local process; reflex and cooperative access control; processes between DPU's; intrusion, security and safety; guard tour; facility management system; video switching, audio switching; time Attendance; events history for alarm or normal events, and archiving; protocol conversions with dedicated controllers, such as J BUS and Modbus, and proprietary protocols, on asynchronous line RS 232 and RS 485; communication with spread sheet for events reporting and for counting report in stand-alone mode; TCP/IP protocol on Ethernet category 5 cable, coaxial cable, fiber optic cable; primary to primary protocol (interruption) between DPUs; primary to secondary protocol (polling) with dedicated panels or controllers; and, communication with standards Fieldbus, for example Lon Works and IEC/SP 50.

The architecture of the DPU is based on a common hardware and software core. The software modules and hardware interfaces are suited to realize adaptable architectures. This method allows mass customization for all market requirements.

The hardware for the DPU can be based on an embedded PC architecture with a PC 104 I/O bus. The Mother board is the common hardware core. In the presently preferred embodiment, as shown in Figure 1, the mother board 10 comprises: a microprocessor 12, a BIOS 14, DRAM memory slots 16, a flash memory slot 18, a VGA port 20, a mouse port 22, a keyboard port 24, a real time clock and watchdog 26, and PC/104 slots 28 for input output modules.

The DPU is equipped with RJ 45 plugs, push-down blocks and cables. It is advantageously compatible with the structured cabling used in buildings for telephone and computer applications. The input output modules are stackable between themselves and with the motherboard.

The input/output modules are can provide a plurality of features and functions, including for example: module digital inputs; module digital transistor outputs; module digital relay outputs; module analog inputs and analog counter inputs; module analog outputs; module digital counter inputs; module internal device display and keyboard; module Fieldbus IEC/SP 50; module Fieldbus Lon Works; module Ethernet twisted pair; module Ethernet fiber optic; module PCMCIA (modem); module readers inputs; and, module asynchronous serial lines.

An example of an input/output module 30 is shown in Figure 2. The module 30 comprises a bank 32 of output relays, a bank 34 of opto-couplers, a PC/ 104 8-bit connector

36, an HE type input/output connector 38 and inputs/outputs represented by arrows 40. Figure 3 shows a mother board 30 schematically connected to an access control module 42, an EAS module 44, a facility management module 46, and a sensing and tracking module 48. The DPU does not use a hardware approach like conventional controllers or panels. Advantageously, the customization is implemented by the software, the architecture of which is diagrammatically illustrated in Figure 4. The software 60 is arranged as a main program 62, a plurality of process subprograms 64 and a plurality of tables 66. The main program 62 links and runs the process subprograms 64. The process subprograms are dedicated software engines that achieve the desired functions. The tables contain the data that the process subprograms require to operate. The program (software) is stored in a flash memory. The program memory is loaded in the program memory of the controller from a host or from a controller. The DPU can, for example, run a Windows® CE operating system to be compatible with other Windows® based applications.

The process subprograms can include, for example as shown: an input/output process; an access control process; a history process, a guard tour process; a modem process; a protocol conversion process; a diagnostic process; a counting process; and a reflex process. The input/output process utilizes information stored in a priority system table, a reflex system table, a process object system table, a device system table and a point system table. The input/output process also receives input signals from counters and readers, as well as receiving system inputs and generating system outputs. The access control process utilizes information stored in a calendar system table, a time group system table, a time zone system table and the point system table. The reflex process utilizes information from the process object system table. Finally, the modem process provides external communication and transferral of parameters.

Figure 5 is a group of flow charts illustrating the operational sequences between the main program 62 and a number of processes. Process 72 is an input/output process in which a badge number is subjected to a protocol reading and the number is supplied to the main program. Process 74 is a history process, in which a history treatment can be stored in a history file. Process 76 is a reflex process in which the process can respond to a reflex treatment with an action. Process 78 is an input/output process in which a door is opened. Process 80 is an access control process, which determines whether the badge number supplied in process 72 is entitled to access, so that the door can be opened in accordance with process 78. Thereafter, entry of the badge, and the person wearing the badge, can be stored by updating the history file. Figure 6 illustrates the adaptability of the software. Layers 90 of the processes 64 contribute to completion of tasks in circle 92, which is controlled by the flexible software 60 downloaded to the DPU. The DPU uses software, rather than hardware, that is adaptable to the exact required features of the user. The user selects all the functions desired by selecting the corresponding DPU's from a list, and then the system can automatically build the executable program. At that point, the software 60 is loaded in the flash memory. This approach saves money on the component memory cost and increases the flexibility of the system.

The DPU architecture uses a distributed database, which is distributed among the controllers and not stored and/or operated from a host or a supervisor. Installation is simplified. Each DPU possesses the database permitting management of the environment to which the DPU is physically connected, together with and the associated logical environment as defined by the functional process groups. The distributed database is more flexible than the replicated database and safer than the shared database of a client/server. Several functions are implemented in the software of the DPU and designed to provide integrated solutions. A first function is a discordance function, in which logical information is generated if an error occurs in a process and the feedback from this process does not correspond to the object of this process. A second function is parasitic events management, which refers to the principle of treating multiple information that comes from constant passage from a logic state to another of a sensor. A third function is avalanche of information, which refers to the principle of managing an important flow of information that comes generally from the transmission of the same information by many sensors or dedicated controllers. A fourth function is dynamic auto-adaptive memory management, which refers to saving important alarm events if there is not enough memory available inside the DPU during a communication failure with the supervisor. The process replaces the normal events by the alarm events in the history of the DPU. A fifth function is dynamic polling list management, which enables limiting the requests from the supervisor to the DPU only to the activated inputs. This function saves cycling time in the polling function for the supervisor and the DPU.

Claims

What is claimed is:

1. A distributed processing and control system, comprising: a plurality of distributed, non-dedicated processing units; each of said units having a common central processing unit and having a common, distributed software control program stored in the central processing unit; a plurality of dedicated process units, different numbers of which can be coupled to different ones of said central processing units in different combinations to achieve different functions and combinations of functions, said common software control program having a control subprogram for each of said dedicated process units, whereby said distributed process units can be assembled from a standard set of components, said distributed processing units being customized by said combinations of said dedicated processing units and operation of said common, distributed software.

2. The system of claim 1 , wherein said dedicated process units comprise at least one of: digital inputs; digital transistor outputs; digital relay outputs; analog inputs and analog counter inputs; analog outputs; digital counter inputs; internal device display and keyboard; Fieldbus IEC/SP 50; Fieldbus Lon Works; Ethernet twisted pair; Ethernet fiber optic; PCMCIA modem; readers inputs; and, asynchronous serial lines.

3. The system of claim 1, wherein said dedicated process units are stackable on said central processing unit and on one another.

4. The system of claim 1, wherein said distributed process units form part of a large control network for a work site.

5. The system of claim 4, wherein said work site is at least one of: a manufacturing facility; a warehouse facility and, a retail merchandising facility.

6. The system of claim 5, wherein said distributed processing units control access of persons to said facility.

7. The system of claim 5, wherein said distributed processing units control movement of articles out of said facility.

8. The system of claim 5, wherein said distributed processing units control movement of articles into and out of said facility.

9. The system of claim 5, wherein: said distributed processing units control movement of articles into and out of said facility; and, said distributed processing units control access of persons to said facility.

10. The system of claim 5, wherein said distributed processing units control movement of persons into and out of said facility.