This invention relates to a configurable monitoring system and method. In particular, this invention relates to a user configurable system and method for remotely monitoring a process or product. The configurable system and method for remotely monitoring a process or product can be configured locally or remotely using an application software.
Various types of remote monitoring sensors are available in the marketplace which have a preconfigured monitoring function. However, this functionality is often limited by the number and type of sensors hardwired onto the device and its hardwired processing and logic capabilities, and, as such, offers few possibilities to customise the monitoring function of the device, and no chance to add functionality without additional accessory devices or sensors being connected thereto.
To overcome these limitations in the prior art, it is an object of the present invention to provide a remote monitoring system and method having user configurable functionality. The functionality of the device is configured using a graphical user interface or application software. These device settings are synchronised or downloaded to the monitoring device via a wireless network. In this way, different users can customise the behaviour of the remote monitoring device and can tailor its functionality, without the intervention of the manufacturer. The present invention provides for much increased functionality and flexibility of the remote monitoring device, with no additional accessory or hardware costs.
According to the present invention there is provided a system for remotely monitoring a process or equipment, comprising:
Preferably, the process is a process used in the manufacture of pharmaceutical products and/or the equipment is pharmaceutical process equipment.
Further preferably, the pharmaceutical process equipment comprises at least one valve or coupling.
In use, the pharmaceutical process equipment may comprise an extraction and/or filtration system.
Preferably, the pharmaceutical process equipment comprises a glove box containment apparatus.
Further preferably, the at least one valve or coupling is a powder transfer valve or coupling.
In use, the valve or coupling may be selected from the group consisting of split butterfly valve, split sliding gate valve, split ball valve, twin valve, rapid transfer port and alpha beta port.
Preferably, the processing means is positioned on an actuator.
Further preferably, the actuator comprises a manually-operable handle having an elongate shaft; one end of the shaft being rounded or dimensioned to form a knob; the other end of the shaft being dimensioned to form a central hub.
In use, the central hub may comprise a first face for connection to the valve or coupling and an opposite second face that is visible to the operator.
Preferably, the first face of the central hub comprises a socket dimensioned to connect with a square spigot on the valve or coupling.
Further preferably, the central hub defines a generally circular body into which a printed circuit board, battery and liquid crystal display is contained.
In use, the central hub may define a sealed, ingress protected enclosure.
Preferably, the processing means and communciation means are located on the printed circuit board.
Further preferably, the processing means is implemented in a low power microcontroller.
In use, the processing means may receive a wake-up signal from user input buttons and/or from the one or more sensed outputs representative of one or more environmental conditions and/or process parameters and/or equipment conditions embedded on, or remote to, the printed circuit board.
Preferably, the system may comprise display means for displaying at least one output signal to an operator via audio-visual, alphanumeric and/or haptic information.
Further preferably, the one or more sensed outputs representative of one or more environmental conditions and/or process parameters and/or equipment conditions is selected from the group consisting of ambient temperature, process temperature, flow rate, light intensity, humidity, atmospheric pressure, process or material pressure, force measurement, operation time, power usage.
In use, the one or more sensed outputs may be selected from the group consisting of photodiode, photoresistor, photodetector, resistance temperature detector, thermocouple, thermistor, piezoelectric, potentiometer, strain gauge, air flow sensor, anemometer, microphone, proximity sensor, motion sensor, Hall effect sensor.
Preferably, the at least one output data string dependent on the one or more sensed outputs is an error, misuse, or fault condition.
Further preferably, the error, misuse, or fault condition is transmitted back to a remote server using a wired or wireless communications means.
In use, the processing means may include a GPS location module which records the location of the process or equipment.
Preferably, the processing means includes a unique identifier.
Also according to the present invention there is provided a system to monitor a process or equipment, comprising:
Further according to the present invention there is provided a method of remotely monitoring a sensing device connected to a network, the sensing device comprising a microprocessor for receiving one or more sensed outputs representative of one or more environmental conditions and/or process parameters and/or equipment conditions, the method comprising the steps of:
Preferably, the method further comprises the steps of:
Further preferably, the method further comprises the step of:
In use, the method may further comprise the step of:
Preferably, the method further comprises the step of:
Further preferably, the step of selecting a subset of the one or more sensed outputs further comprises disabling one or more sensed outputs representative of one or more environmental conditions and/or process parameters and/or equipment conditions.
In use, the step of defining at least one configurable output data string further may comprise defining at least one error, misuse, fault and/or event condition based on the subset of sensed outputs.
Preferably, the step of transmitting the at least one configurable output data string populated by the at least one error, misuse, fault and/or event condition over a network.
Further preferably, the selecting and defining steps of the method are carried out using a graphical user interface and/or application software.
Also further according to the present invention there is provided a computer program product for remotely monitoring a sensing device connected to a network, the sensing device comprising a microprocessor for receiving one or more sensed outputs representative of one or more environmental conditions and/or process parameters and/or equipment conditions, comprising:
It is believed that a system and apparatus in accordance with the present invention at least addresses the problems outlined above. The advantages of the present invention are that a remote monitoring device can be placed on or in the vicinity of a product or process which enables the sensing of one or more environmental conditions and/or process parameters and/or equipment conditions. Advantageously, the present invention provides a remote monitoring device and method having user configurable functionality. Different users can customise the behaviour of the remote monitoring device and can tailor its functionality, without the intervention of the manufacturer. The present invention advantageously provides for much increased functionality and flexibility of the remote monitoring device, with no additional accessory or hardware costs. Further advantageously, the software that is running on the remote monitoring device can be significantly changed or configured remotely via the graphical user interface or application software running on an internet connected server. The user is able to make significant changes to the look and functionality of the remote monitoring device and its user interface; turning on and off sensors, and altering the types of data that is recorded and the data that is transmitted to the server. Further advantageously, the application software for customising the behaviour of the remote monitoring device provides a user friendly and intuitive interface.
It will be obvious to those skilled in the art that variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.
Specific non-limiting embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which:
Referring now to the drawings, the system and method according to the present invention has been developed for incorporation into any type or form of remote monitoring device. Such a remote monitoring device can be utilised for sensing one or more environmental conditions and/or process parameters and/or equipment conditions in the vicinity of the remote monitoring device.
To allow for user configurable device settings to be written in a graphical user interface or application software and then synchronising the device settings to the monitoring device via a wireless network, the present invention makes use of a remote customisation method. Further detail on each aspect of the method is described in relation to
Whilst the present invention has been developed specifically for the remote monitoring of one or more environmental conditions and/or process parameters and/or equipment conditions on, or in the vicinity of, valve assemblies for controlling, charging, discharging and/or regulating the flow of powders, liquids, slurries, tablets and/or fluid, this is in no way intended to be limiting as, in use, the remote monitoring device can be utilised in many different types of industries and applications.
Remote monitoring of one or more environmental conditions or and/or process parameters and/or equipment conditions can include, but is not limited to, monitoring of ambient temperature, process temperature, flow rate, light intensity, humidity, process level, atmospheric pressure, density, process pressure, pH measurement, force measurement, fluid velocity, satellite position, position, angle, displacement, distance, speed, acceleration, sound, vibration, frequency, proximity, ionising radiation, electric current, electric potential, signal measurement, operation time, power usage. In addition, the skilled person will appreciate that environmental conditions are often inextricably linked with process parameters. For example, environmental conditions, such as relative humidity, can significantly affect the behaviour of various powders, dust, granular and semi-solid ingredients. Equally, equipment conditions, such as excessive wear on the viscoelastic valve components and seats, can significantly affect the process parameters and/or may be used to predict critical valve failure.
The method of remotely customising the remote monitoring device, via a website, is illustrated in
At S10, the user would firstly log on to a website. The website is effectively a portal that will allow all interactions (inputs/outputs) with the remote monitoring device.
At S12, the user enters the unique identifier of the remote monitoring device that is being configured. The unique identifier of the remote monitoring device then brings up basic information about the device, which would have already been pre-loaded to the website at the manufacturing stage. Alternatively, the basic information about the device is stored on the device, and that can be accessed via a web address linked to the device. The basic information about the device can include, but is not limited to, basic hardware and software configuration, battery type and capacity, information on the number and type of internal and external environment and equipment sensors, initial input and display settings etc.
Once the device has been identified, at S14, it would be linked to the account of the user, and further information about the identity and location of the remote monitoring device could be entered at S16. For example, the room number or building name could be entered, or the process equipment to which the device is fitted to could be listed. The further information, at S16, can also include the unique identifier of the machine or process to which the remote monitoring device is fitted or associated with.
At S18, the user can select, via the website, the basic functionality platform for the device (or multiple devices) from a range of options. An example could be a “filter monitoring” platform, or “movement detection” platform or “electric motor monitoring” platform etc.
Each basic functionality platform has a set of default software elements which makes the device suitable for monitoring a different set of environmental conditions and/or process parameters and/or user inputs.
As the device has a range of sensors which may or may not be suitable for each application, by choosing the platform the user is selecting which sensors they would like to use, and in which way, for their particular application.
For example, the “filter monitoring” platform could enable the pressure sensors contained in the device and disable the accelerometer sensors, and the software would then display information to the user that was suitable for measuring a pressure differential across a filter element.
The platform would also provide a number of default “events” for the user to choose from. An “event” is when a change in the sensed data from the sensors is deemed important enough to be recorded. The change in data is given a name and the time and date when it occurs is recorded. An example would be an event called “rotation” which is when an accelerometer detects rotation about a certain threshold and the exact time and date of the occurrence of the rotation is recorded.
The skilled person will appreciate that the number of basic functionality platforms available can be added to in time as more platforms are released for use.
The next step, at S20, is for the user to configure the functionality of the remote monitoring device. The user could choose which “events” they would like to select from those initially offered in the basic functionality platform default list available, or alternatively select other “events” that were not initially offered. The user could also select what screens and options that the end user of the remote monitoring device would see in the device's local display, again selected from a range of default options, and define any error, misuse, or fault operations or conditions.
The following step, at S22, would be to set the event parameters on the remote monitoring device. An “event” might be a sensed condition or input stimuli that would cause caution or alarm (for example a maximum temperature being exceeded), or when a combination of readings (e.g. a pressure differential across a filter element) would be considered to be an event that should be otherwise recorded.
Other additional parameters would also be set at this stage might include setting the time interval between remote synchronisations of the device with the website server, and other time-based functionality.
At S24, the user would then select a visual and audible style for the remote monitoring device from a range of options. This would be tested via an emulator on the website that would enable the user to experience the look of the display screen on the remote monitoring device and the reaction of the device to different input stimuli.
The user would further personalise the remote monitoring device by inserting additional text, altering the font, background colours and inserting desired icons, logos or images.
At S26, the user is then prompted to save the completed software file on the website, ready to be installed on a single remote monitoring device, or multiple devices, depending on what was selected at S12. The user can synchronise the software on the device by either waiting until the next default data transfer is scheduled to take place, or they can prompt or “force” a transfer by manually selecting the option on the device.
The microcontroller 52 can be considered a self-contained system with a processor, memory and peripherals and can be used to display local information to the end user via a number of outputs generally indicated in the left hand side of element 50.
In operation, a set of instructions or algorithm written in software in the microcontroller 52 are configured to program the microcontroller 52. In use, the microcontroller 52, including the processor, memory and peripherals, can be firstly placed in a low power, standby mode, awaiting a wake-up signal. The wake-up signal can be received from the user input buttons and/or from one or more environmental sensors 54 embedded on the printed circuit board and/or from one or more equipment sensors 66, environmental sensors 64 and/or user inputs 62 and/or process sensors (not shown in
In addition or alternatively, the microcontroller 52 could effectively be woken-up from low power standby mode by any number of input stimuli. In one embodiment, one of the equipment sensors 66 is a positional sensor which senses the rotational position of an operator handle relative to a valve assembly. In use, the positional sensor is a three-axis accelerometer, and which is receptive to small input stimuli including rotation, pulse, shock, impact and/or vibration to firstly awaken the microcontroller 52. The skilled person will appreciate that the positional sensor could also be implemented using other multi-axis accelerometers, such as a six-axis accelerometer, or by the use of rotational optical encoders or on/off sensors and switches.
The one or more equipment sensors 66, environmental sensors 64 and/or user inputs 62 and/or process sensors (not shown in
When the microcontroller 52 has been woken-up, it then senses the output of the three-axis accelerometer to determine the orientation and position of the rotation of the valve-actuating handle. If the output of the three-axis accelerometer corresponds to one or more of the predetermined events that have been configured on initialling customising the device 50, the event would be considered to be an event that should be otherwise recorded. In this example, the event written in software could be called “rotation” which is when an accelerometer detects rotation about a certain threshold and the exact time and date of the occurrence of the rotation is recorded.
In a preferred embodiment, only the information relevant to each individual event are recorded to preserve battery life and reduce local storage requirements. The device can also be configured to sample and record in memory all of the outputs of the one or more environmental sensors 54 embedded on the printed circuit board and/or from one or more equipment sensors 66, environmental sensors 64 and/or user inputs 62 and/or process sensors (not shown in
The skilled person can also appreciate that the device can be configured simply as a data logger, reading and recording the output of the one or more of the sensors with a fixed or variable sampling rate.
The display unit 72 on the remote monitoring device 50 can be used to display the obtained sensed data to the end user, as configured at S24, and/or can include one or any combination of output signals to the display unit 72, such as an audible output or alarm 74 or some form of haptic feedback 76.
For the example, the display 72 could be used to display the number of times the valve has been opened or closed, and also display additional information such as the service life data, or the output of any of the environmental sensors 64 which record conditions such as external/internal temperature, light intensity, humidity, atmospheric pressure, force measurement and operation time. The one or more sensors 54 embedded on the printed circuit board and/or the one or more environmental sensors 64 positioned remotely to the microcontroller 52 can be selected from the group consisting of photodiode, photoresistor, photodetector, resistance temperature detector, thermocouple, thermistor, piezoelectric, potentiometer, strain gauge, air flow sensor, anemometer, microphone, proximity sensor, motion sensor, Hall effect sensor.
If the output of the sensors 54, 64 corresponds to one or more of the predetermined events that have been configured on initialling customising the device 50, that event would be recorded. The event could be an overtemperature or other process or environmental condition, as configured on initialling customising the device 50. As explained, an example would be an event called “rotation” which is when an accelerometer detects rotation about a certain threshold and the exact time and date of the occurrence of the rotation is recorded in memory.
In addition to recording specific events, the microcontroller 52 could also record the total time that the valve has been in use, and the temperature that the valve has been exposed to, as configured by the user on initialling customising the device 50. These may be received from one or more environmental sensors 54 embedded on the printed circuit board and/or one or more environmental sensors 64 positioned remotely to, but in the vicinity of, the valve. The interaction of the operator with the device, via input buttons 54 (or via any other input/output means) can also be monitored and stored.
As well as the microcontroller 52 outputting the sensed one or more environmental conditions or process parameters in the vicinity of the sensing device, it is envisaged that this information can be stored in local memory for further local or remote analysis. This information can be accessed locally and/or transmitted back to a central database 84 connected via the internet 72 using a communications unit 70 which may be a suitable wired or wireless communication protocol 78, including for example, Bluetooth, ZigBee, or over a cellular network.
Captured information can be transmitted from the microcontroller 52 to central database 84 or dedicated web server or web-enabled device which is local 88 (i.e. on-site) or remote 86 (i.e. off-site).
Whilst data transmission can occur via a wired network, in a preferred embodiment, data transmission is over a wireless network which has advantages in terms of lower cost and quicker installation. The data is then available to a user online via the local 88 or remote devices 86. In this way, one or more appropriately authorised users can access the captured information obtained from the remote monitoring device 50.
The skilled person can also envisage that the present invention can be provided in a number of self-contained monitoring units 50 monitoring a number of valves or sensing of one or more other environmental conditions or process parameters at locations situated throughout a production line or facility. Each communications unit 70 of the device 50 can then be configured as a node of a wireless mesh network system which provides a very robust network, as each node only needs only transmit as far as the next node. Nodes act as routers to transmit data from nearby nodes to peers that are too far away to reach in a single hop, resulting in a network that can cover larger distances.
It is desirable that the wireless network has low power consumption, enabling several years of operation between battery changes.
As an alternative to the wireless network described hereinbefore, transmission of the data may occur over a WiFi network.
It is also envisaged that the microcontroller 52 could also include or has embedded therein a GPS location module 56 which records the actual location of the device 50. If configured by the user, these parameters could be stored in local memory and transmitted back to a central database 84, via the communications unit 70, when the next preconfigured data transfer is scheduled to take place.
The device is battery-powered and sealed to the environment (i.e. ingress protected) and safe for used in hazardous and/or potentially explosive environments (e.g. ATEX rated). The microcontroller 52 utilises low power components so that the system is designed to provide a long battery life.
As shown in
The front face of the hub 118, i.e. the face that is visible to the operator, is generally circular in shape.
As best shown in
As the valve-actuating handle 140 is intended to be used in environmentally-challenging conditions, including containing, regulating and controlling hazardous powders, dust, granular and semi-solid ingredients, the housing 106 and screen sub-assembly 110 are secured together using assembly screws 116 and internal O-ring seals 126 which secure the housing 106 and screen sub-assembly 110 to the hub 118 against a circumferential seal 124.
To provide functionality, the PCB 100 includes various hardware, software, sensors and components, as described in detail in relation to
In an alternative embodiment, the hub 118 would be secured to the split valve assembly 150, with the valve-actuating handle 140 being rotatable within the body of the hub 118 to rotate the socket. In this manner, the LCD display 108, and the operation and/or function buttons 114 positioned around the radius of the screen sub-assembly 110, are positioned in a fixed orientation for the user.
As shown in
Although not shown in
The valve closure members are seated on annular valve seats (not shown) defined inside the valve housings 158, 160. The valve seats are resiliently deformable and are generally located in respective recesses for receipt of the seat which, in use, is adapted to engage against a solid portion of the valve housings 158, 160.
The valve closure members are adapted to be pivotable through 90° or beyond, thus when in its fully open position the profile of the face of the valve closure members corresponds with the profile of the through bore of the valve housings 158, 160, and thereby provides minimal restrictions for the flow of fluid or other material.
Whilst the foregoing describes how the present invention can be embodied in a valve-actuating handle 140 for manual operation of a valve or coupling, and particularly a split butterfly valve assembly 150, the skilled person will appreciate that the invention can be implemented in any manner of transfer valve or coupling, such as, for example, split sliding gate valves, split ball valves, twin valves, rapid transfer ports and alpha beta ports.
Various modifications may be made to the present invention without departing from the scope of the invention. For example, although particular embodiments refer to implementing the present invention as a remote monitoring device on a valve or coupling, this is in no way intended to be limiting as, in use, the present invention could be implemented in any machine, process, equipment, product or asset where sensed information is desired. The invention is not restricted to the details of the foregoing embodiments.
Number | Date | Country | Kind |
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1413713.7 | Aug 2014 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2015/052206 | 7/30/2015 | WO | 00 |