Patent Application
20170052524
Not applicable
Not applicable
I. Field of the Invention
The present invention relates to setting up, configuring, monitoring and controlling field devices for a plant. More specifically, the present invention relates to field devices in a plant and universal setting up, configuring, monitoring and controlling of such field devices wirelessly using a commercially available, of smartphone or tablet computer.
II. Related Art
Many manufacturing facilities and other plants utilize various types of field devices to control processes carried out in the plant. Typical examples of such field devices include valves, pumps, motors, conveyors, dampers and various other mechanical, electrical and electro-mechanical devices. Efforts to automate such plants are well known in the prior art. Such automation efforts typically involve the use of one or more distributed control systems (DCS) or programmable logic controllers .(PLC) to monitor and control the field devices. The DCS or PLC is typically hard-wired to the field devices to be controlled. The wires carry power, data and commands between the field devices and the PLC or DCS.
Various attempts have been made to provide wireless communications rather than wired communications. These wireless communications have typically been carried out using wireless wireless devices, i.e., wireless devices specifically designed to communicate with a specific field device. Since plants typically include different types of field devices, operators have been required to carry or have access to separate wireless devices matched to the different types of field devices.
Also, in the prior art, specialized master devices adapted for a specific field protocol have been used. These specialized master devices are designed to implement mission critical, plant specific, specialized operating protocols. As such, these devices tend to be quite cumbersome to use and are not suitable for more general use.
Instrument technicians and plant maintenance staff for many years have been looking for a single, wireless, commercially available, off-the-shelf device able to communicate with each of the various types of field devices used in various plants to setup, configure, monitor and control such field devices.
The present invention solves the problems highlighted above by providing wireless setup, monitoring and control of many different types of field devices using a single smartphone such as an Apple® iPhone® or a single tablet computer such as an Apple® iPad®. This is achieved using Bluetooth® wireless technology built into the smartphone or tablet computer capable of carrying out two-way communications with controllers coupled directly into the field devices.
More specifically, a setup, monitor and control apparatus is provided. The apparatus includes a plurality of field devices which may be valves, motors, conveyors, dampeners or other mechanical, electrical and electro-mechanical devices used in a plant. Each of the field devices is coupled to a communications and control module (CCM). The field device is also typically coupled to at least one actuator controlling a function of the field device, and a sensor for monitoring a condition of either the field control device or the at least one actuator. The sensor is adapted to send signals to the CCM. The CCM is adapted to process such signals and control the operation of the at least one actuator. Further, the CCM includes a human machine interface (HMI), a processor, a clock, at least one memory module and a first short range radio adapted for two-way communication. A very suitable first short range radio is incorporated in a Bluetooth RF module. Bluetooth RF modules typically have a range of less than 100 meters. The processor, pursuant to a preselected set of instructions, is adapted to (i) store in said at least one memory module identification and address information concerning the field device and CCM, (ii) store information based on signals received from the at least one sensor and processed by the processor, (iii) send control signals to the at least one actuator, (iv) retrieve data from memory and transmit such data using the first short range radio, and (v) receive and process command signals received using the first short range radio.
The apparatus further comprises general purpose, commercially available, off-the-shelf mobile device (“GPMD”). Many GPMDs are suitable for use in non-hazardous operating environments. Many are also suitable for use, with or without modification, even in hazardous operating environments. When modification is required for use in hazardous environments, the modification may he as simple as providing a protective case for the GPMD. The GPMD may, for example, be a smartphone such as an Apple-iPhont® or a tablet computer such as an Apple® iPad®. Such GPMDs have a display, typically a touch screen display. Such GPMDs also include a second short range radio (most often a Bluetooth RF module) well-suited for communication with the first short range radio of each CCM attached to each of the plurality of field devices. When the GPMD and the CMM are within the range of the first and second short range radios, they are able to communicate with each other. Such GPMDs also include their own processor, memory module, user interface and operating system.
An important aspect of the present invention is the manner in the GPMD can be (and is) controlled, at least in part, by an application program which adapts the GPMD to interrogate each CCM in range of the first and second short range radio modules to retrieve and display identification information related to each such CCM. The user interface permits the GPMD, based on inputs from a user, to selectively send control signals to each such CCM. On a selective basis, the GPMD is also able to interrogate each such CCM to obtain and display information related to the operation of the field device attached to the CCM.
These and other attributes, features and advantages of the present invention will become more apparent to one skilled in the art from a review of the drawings provided herewith in conjunction with the detailed description provided below.
This description of the preferred embodiment is intended to be read in connection with the accompanying drawings, which are to be considered part of the written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top”, and “bottom”, as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of the description and do not require that the apparatus be constructed or operated in the orientation shown in the drawings. Further, terms such as “connected”, “connecting”, “attached”, “attaching”, “joined”, and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressly described otherwise.
Eight field devices 1-8 are shown in
In
The CCMs 10 are capable of conducting two-way communications with a GPMD such as smartphone 22 or tablet computer computer 24 since each CCM 10 and each such smartphone and tablet computer are equipped with a Bluetooth RF module. A unique software application loaded onto the smartphone 22 or tablet computer 24 permits the smartphone 22 or tablet computer 24 to collect and process signals from the CCM 10 of each of the field devices 1-8 within the range of the Bluetooth RF Modules of the CCM and the GPMD. The range of such modules is typically less than 100 meters. The GPMD (smartphone 22 or tablet computer 24) processes those signals to display information related to the identity and status of each such CCM and attached field devices 1-8. The application also permits the user of smartphone 22 or tablet 24 to send commands and data to and receive data from the individual CCMs 10 associated with the field devices 1-8.
For automated control of a field device 30, it is also necessary to sense the operating condition of the field device 30 or the actuators 32 and 34. A sensor 36, which may be a temperature sensor, is shown in
Control of the actuators 32 and 34 to thereby control operation of the field device 30 is provided by the field device controller 18 of the CCM 10. Controller 18 comprises a microprocessor or micro-controller module 50 (herein either of which are generically referred to as a processor), a clock 52, non-volatile memory module 54, a volatile memory module 56 and a human machine interface (HMI) 58. As illustrated, the HMI 58 includes a set of indicator lamps 60, 62, 64, 66 which provide the user with information regarding the operating condition of field device 30 and actuators 32 and 34. The indicator lamps may, for example, be light emitting diodes (LEDs). HMI 58 also includes a set of switches 70 and 72 which allow a user to set the operating condition of the field device 30 or control the actuators 32 and 34. Power is supplied to the field device 30 and to the attached CCM 10 by the bus 82. Alternatively, power can be supplied by a battery or by a separate electrical connector. The processor 50 performs a variety of control and reporting functions based upon a preprogrammed set of instructions stored in the non-volatile memory module 54, signals from the sensors 36-42, signals from the clock 52, signals from the HMI 58, commands received from the PLC 14 or the computer 16 via the PLC 14 shown in
Control functions performed by the processor 50 include sending signals to the actuators 32 and 34 to control the operation of the field device 30. The control functions performed by the processor also include controlling the operation of the LEDs 60-66 of the HMI 58 so that the LEDs properly indicate status information to a user who happens to be within the field of view. The control functions performed by processor 50 also may include locking switches (buttons) 70-72 of the HMI 58 to disable the functionality of the switches and unlocking the switches to restore their functionality.
Reporting functions performed by the processor 50 include polling the sensors and processing signals from the sensors, storing information derived from such processing in the volatile memory module 56 and sending such information to the HMI 58, the computer 16 when commanded to do so by the PLC 14 or to the smartphone 22 or tablet computer 24. By way of example, and without limitation, when the field device 30 is a valve, the processor 50 will illuminate the “open” LED 60 of the HMI 58 when the valve is open and illuminate the “closed” LED 62 of the HMI 58 when the valve is closed. Likewise, the processor 50 will illuminate the solenoid 1 LED 64 of the HMI 58 when actuator 32 is operating and the solenoid 2 LED 66 when the actuator 34 is operating. These LEDs are off when the actuators 32 and 34 are not operating.
Additionally, the processor 50 can record historical data related to the operations of the field device 30 and actuators 32 and 34 for later reporting. For example, if sensor 36 is a temperature sensor, the processor 50 may store in the non-volatile memory module 56 the current operating temperature of the field device 30, the highest operating temperature of the field device 30, the lowest operating temperature of the field device 30, or the operating temperature of the field device 30 at discrete time intervals based on signals from the sensor 36 and the clock 52. Likewise, the processor 50 can record in the non-volatile memory module 56 for later reporting information related to the operation of the actuators 32 and 34 based on signals from the sensors 40 and 42. Such information may include the number of times each actuator was operated and the time and duration of each such operation. Data from the sensor 38, when it is a position sensor, may be used to record the number of cycles of the field device 30 or whether the field device 30 is actually positioned (or otherwise operating) as desired. These signals can also be used by the processor 50 to provide feedback control to the actuators 32 and 34.
The raw or processed sensor data may be reported to the PLC 14 in real time, at pre-selected time intervals or upon requests that the processor 50 receives from the PLC. Likewise, the raw or processed sensor data may be transmitted by the processor 50, via the Bluetooth module 20, to the smartphone 22 or tablet computer 24.
In addition to processing and reporting data from the sensors, the processor can store, process, respond to and report instructions and data transmitted between the CCMs 10 and PLC 14 or between the CCMs 10 and the smartphone 22 or tablet computer 24. By way of example, the PLC 14 can send an instruction to the processor 50 controlling how the processor responds to instructions received from a smartphone 22 or tablet computer 24. More specifically, the PLC 14 can instruct the controller regarding what commands to accept and process from smartphones 22 or tablet computers 24 generally or from a specific smartphone 22 or tablet computer 24. The way in which the processor 50 is also adapted to respond to commands from the PLC 14 limiting the data shared with smartphones 22 and tablet computers 24 generally or with a specific smartphone 22 or tablet computer 24 is further explained below.
The memory modules of 54 and 56 are also used to store identification information related to the specific field device 30 attached to the CCM 10. Such information includes the model number of the field device 30, a unique ID tag identifying the field device 30 and attached CCM 10, other address and communications information (e.g., the baud rates at which the CCM can communicate) related to the CCM, description information related to the field. device 30 attached to the CCM, other user-supplied information, linking data related to the website of the manufacturer or supplier of the field device 30 or CCM 10 attached thereto, and linking data related to an electronic copy of the instruction manual available via the Internet for the field device 30 or CCM attached thereto.
Readers familiar with Bluetooth RF modules understand that they have their own processor and memory module in addition to the two-way radio. The memory of the Bluetooth RF Module may be used to store certain types of data associated with the CCM 10 and the attached field device 30 without deviating from the invention. Further, in some embodiments, and without deviating from the invention, it may be possible for the CCM 10 to rely for its operation exclusively on the processer of the Bluetooth RF module to reduce the number of components and the cost of manufacture associated therewith. This may become more likely as the processing power of the processors built into Bluetooth RF modules increases or for other reasons.
A “wink” button 106 is associated with each of the three devices identified on the display of
Also associated on the display of
Before turning to a discussion of
There are alternative ways to switch the CCM 10 between the locked and unlocked condition. For example, the CCM 10 may default to the locked condition, but switch to the unlocked condition whenever a predetermined voltage is applied to the CCM and the CCM is not receiving a master control signal from a controller such as the PLC. Alternatively, the CCM 10 could default to an unlocked condition, but switch to a locked condition whenever it is under master control and receiving communication signals from a PLC or some other master controller. A preauthorized password transmitted from the GPMD to the CCM could also be used to unlock the CCM.
In
Command buttons shown in
Additional information is provided in
To populate the current temperature field, the processor 50 processes data directly from the temperature sensor 36 or interrogates the memory module 54 to retrieve the last reported and stored temperature. This data is then delivered to the phone or tablet computer via the Bluetooth RF module 20. Upon arrival at the phone or tablet computer, the data is further processed for display in accordance with instructions contained in the application software loaded into the phone or tablet computer. Likewise, the date required to populate fields 164-168 are retrieved from memory module 54 by the processor 50 and transmitted to the phone or tablet via the Bluetooth RF module 20. Upon receipt by the phone or tablet, the data is processed by the processor of the phone or tablet computer, stored in the memory of the phone or tablet computer, and the appropriate fields are populated on the display of the phone or tablet computer.
When either of the reset buttons 170 and 172 are depressed, an addressed signal is sent by the phone or tablet computer to the Bluetooth RF module 20 of the CCM. Upon receipt, this signal is processed by the processor 50 and the memory locations in the memory module 54 storing the relevant data are cleared, More specifically, when reset button 170 is pressed, the memory locations storing the minimum and maximum temperatures are cleared and when the reset button 172 is pressed, the memory location storing the cycle count is cleared. The processor 50 will repopulate those memory locations with new data based on readings from the appropriate sensors (e.g. 36 and 38).
Two free-form fields 180 and 182 are shown in
If the smartphone or tablet computer is connected to the internet, two other features are enabled. Pressing the website button 190 will send a command to the CCM 10 causing the processor 50 to access the aforementioned website linking information stored in the memory module of the CCM 10 and forward the linking information to the smartphone or tablet computer via the Bluetooth RF module 20 to launch a web browser of the phone or tablet. This may allow the user to view the website of the manufacturer or supplier of the field device using the web browser of the smartphone or tablet computer. Hitting the installation manual button 192 will cause the installation manual for the field device to be downloaded and displayed using the relevant linking information stored in the memory of the CCM.
Use of the smartphone or tablet computer is not limited to monitoring and control of the field devices and attached CCMs in the plant. The apparatus described above may also be employed for configuration of the field devices and attached CCM at the time of manufacture at the factory and/or at the time of installation at the plant.
At the factory, a predetermined voltage is applied to the CCM 10 to switch the CCM 10 from a locked condition to in an unlocked condition. Using the GPMD the smartphone or tablet computer), a pre-determined, but unpublicized sequence of actions are performed within a predetermined time window to cause the GPMD to display a login screen. An administrative password is then entered. Upon entry of a preauthorized administrative password, a setup signal is sent by the GPMD to the CCM. Upon receipt of this signal, the CCM switches from the unlocked condition to a setup condition. Also, at least one settings page is displayed on the GPMD. Various factory settings and data are provided by completing fields on the settings pages. Examples of such settings and data include the serial number, model number and date code of the field device. These are then transmitted by the GPMD to the CCM 10 and stored in one of the memory modules of the CCM, e.g. non-volatile memory module 54. Other information may be stored in the memory of the CCM in a similar manner at this time. Additional examples include internet links to the manufacturer's website and to an electronic copy of the instruction manual for the field device and CCM. After the desired configuration data has been delivered to and stored in the memory of the CCM, the user logs out. At logout, a signal is sent to the CCM causing the CCM to switch from the setup condition back to the unlocked condition thereby disabling the ability to enter or change the settings information until a preauthorized administrative password entered again.
Other information can be supplied in a similar fashion at the time of installation of the field device and CCM at the plant. Such information typically might include the address of the CCM, a code indicative of the address type (e.g., 1=“As-i Address”, 2=“AS-i Address +A or B”, 3=“DeviceNet Address”), a code indicative of a specific baud rate for communications, etc. Likewise, the memory locations in which temperatures, cycle counts and the like are stored can be cleared and the sensors can be calibrated thereby prepared for use.
It is also possible to automate the process of setting up a series of field devices and associated CCMs. In addition to the above-described application residing on the general purpose mobile device, a spreadsheet containing the specific setup data for each of the series of field devices and attached CCMs may be prepared and loaded onto the general purpose mobile device. A macro is also loaded onto the general purpose mobile device which operates to extract data from the spreadsheet and supply it to the application in a way that causes the application to load forward the data to the CCMs for storage in the memory of the CCM.
The foregoing description is intended to explain, but not limit the invention which is defined by the following claims. As noted above, various types of field devices may be used. The specific design of a CCM may be adapted to the particular type of field device with which it is used. A GPMD other than a smartphone or tablet computer may be used. The GPMD may employ a communications protocol other than Bluetooth. The CCMs may be altered to enable use of a GPMD using a communications protocol other than Bluetooth. These and other modifications may all be made without deviating from the invention.
