Smart functionality for discrete field devices and signals

A method for managing discrete signals in a process plant, the method comprising:

• receiving a plurality of discrete input signals, at a process control device, via a first communication interface including a plurality of input/output (I/O) connectors connectable to a plurality of discrete I/O channels that couple the process control device to one or more field devices;
• decoding each of the plurality of discrete input signals to identify a plurality of sets of information;
• encoding a message with the plurality of sets of information;
• and
• transmitting, via a second communication interface configured to be coupled to a communication channel coupling the process control device to a signal characterization component coupled to an I/O card for a process controller, a discrete signal carrying the message so that the process controller can:
• (a) receive the plurality of sets of information, and (b) implement control based on the plurality of sets of information, wherein the signal characterization component is external to a housing of the I/O card.

A process control device for managing discrete process signals associated with a field device in a process plant, the process control device comprising:

• a first communication interface configured to be coupled to a plurality of discrete I/O channels connected to one or more field devices;
• a second communication interface configured to be coupled to a communication channel linking the process control device to a signal characterization component disposed in a housing coupled to an I/O card, disposed external to the housing of the signal characterization component, for a process controller;
• one or more circuits communicatively coupled to the first communication interface and to the second communication interface, the one or more circuits configured to:
• (i) receive, via the second communication interface, a discrete signal carrying a message;
• (ii) decode the message to identify a plurality of commands carried by the message;
• (iii) encode the plurality of commands onto a plurality of discrete output signals such that each discrete output signal carries a different one of the commands;
• and
• (iv) transmit, via the first communication interface, each of the plurality of discrete output signals so that each of the plurality of discrete I/O channels to the one or more field devices carries a different one of the plurality of discrete output signals.

A method for managing discrete process signals in a process plant, the method comprising:

• receiving a discrete signal, at a process control device and via a channel coupling the process control device to a signal characterization component coupled to an I/O card for a process controller, the signal characterization component external to a housing of the I/O card and the discrete signal carrying a message;
• decoding the message to identify a plurality of commands carried by the message;
• encoding the plurality of commands onto a plurality of discrete output signals such that each discrete output signal carries a different one of the commands;
• and
• by way of a plurality of discrete I/O channels coupling the process control device to one or more field devices, transmitting each of the plurality of discrete output signals so that each of the plurality of discrete I/O channels carries a different one of the plurality of discrete output signals.