System and method for industrial process control

Abstract

This disclosure relates to a process control unit for controlling a process wherein the controller utilizes hardware and modular software to accomplish the control. The modular software for interfacing the process with the user allows the user to utilize predefined software interfaces with a human machine interface. A user need only define the text and parameters to be displayed and then map them to a specific element of the human machine interface therein expediting process parameter modification at a later time.

1 . A system for controlling industrial processes comprising: 
 a microcontroller operable to process a plurality of inputs and a plurality of outputs, a human-machine interface, a communication connection, and memory for controlling the industrial process, said microcontroller, plurality of inputs and outputs, human-machine interface and communication connection all resident upon a single circuit board, a software module resident in said memory for interfacing with the human-machine interface, said system capable of being reprogrammed wherein a process parameter is defined and linked to one or more elements of the human machine interface; said human-machine interface operable with a plurality of detachable overlays to facilitate process data extraction and process reprogramming for a plurality of processes.    
   
   
       2 . The system for controlling industrial processes of  claim 1 , wherein the human-machine interface comprises a data entry device and a data display device.  
   
   
       3 . The system for controlling industrial processes of  claim 2 , wherein the data display device is a liquid crystal display.  
   
   
       4 . The system for controlling industrial processes of  claim 2 , wherein the data entry device is a key pad.  
   
   
       5 . The system for controlling industrial processes of  claim 4 , wherein the element of the human machine interface is a key on the keypad.  
   
   
       6 . The system for controlling industrial processes of  claim 1 , wherein defining a process parameter comprises assigning specific text through the human machine interface to the process parameter.  
   
   
       7 . A system for controlling an industrial process comprising: 
 hardware means and software means for receiving a plurality of inputs and sending a plurality of outputs determined by said hardware means and software means;    human-machine interface means for entering process parameters and querying the system for production data;    means for reprogramming process parameters wherein a text set and process parameters are defined; said defined text set and process parameters capable of being linked with one or more elements of said human machine interface; and    overlay means for altering the functionality of the process control system.    
   
   
       8 . The system for controlling an industrial process of  claim 7 , wherein the human machine interface means comprises a data entry device and a data display device.  
   
   
       9 . The system for controlling an industrial process of  claim 7 , wherein the data entry device is a key pad.  
   
   
       10 . The system for controlling an industrial process of  claim 7 , wherein the data display device is a liquid crystal display.  
   
   
       11 . The system for controlling an industrial process of  claim 7 , wherein the element of the human machine interface is a key on the keypad.  
   
   
       12 . The system for controlling an industrial process of  claim 11 , wherein the overlay means comprise a substantially transparent overlay that is disposed atop the keypad to assist in defining the functionality of the keys.  
   
   
       13 . The system for controlling an industrial process of  claim 7 , wherein key functionality is linked to process parameters.  
   
   
       14 . A method for controlling an industrial process comprising: 
 configuring a controller comprising a microcontroller with a plurality of inputs and outputs, a human machine interface, resident memory and communication hardware;    positioning the controller in proximity to the process;    preparing a first program to interface at least one process device to the microcontroller;    preparing a second program to interface a user with the process;    defining text and process parameters;    linking defined text and defined process parameters with an element of the human machine interface;    utilizing an overlay template to identify the element of the human machine interface linked with one or more defined process parameters; and    initiating the industrial process.    
   
   
       15 . The method according to  claim 14 , wherein the element of the human machine interface is a key on a keyboard.  
   
   
       16 . The method according to  claim 14 , wherein the first program to interface the at least one process device to the microcontroller comprises a machine language program.  
   
   
       17 . The method according to  claim 14 , wherein the second program to interface the user with the process comprises a high level programming language.