1. Field of the Invention
The present invention relates generally to an improved apparatus for sensing or measuring a parameter of a process and, more particularly, to a self contained module for providing logging of information in a sensing and measuring device and enhancing data communication between the sensing and measuring device and a process display, control and/or recording device.
2. Description of Related Art
Generally speaking, it is desirable to sense, measure, record and store a plurality of characteristics of commercial or industrial processes. For example, process variable such as, for example, temperature, pressure, strain, resistance, voltage, velocity, and the like, can positively and negatively influence process control and optimization. In view thereof, industry invests substantial resources to accurately sense and measure processes. Typically, a system of process controls employs sensors located at various points in a process. The sensors are coupled to test and measurement instruments that receive data and/or information via signals from the sensors and determine one or more process variables. The test and measurement instruments may include displays and control devices for exhibiting the received signals and/or determined process variables, and for controlling a predetermined response thereto. Typically, data, signals and/or commands are communicated between sensors and the test and measurement instruments over communication paths by means of point-to-point hard wired connections such as, for example, electrical wires, fiber optic lines, or like connections. As can be appreciated, establishing and maintaining such wired communication paths may be time consuming, costly and error prone.
In the aforementioned commonly owned, U.S. patent application Ser. Nos. 11/877,285 and 12/470,969, of which this application relates, a wireless connector is taught. As disclosed in the Background Sections of these commonly owned U.S. patent documents, the test and measurement devices generally include a sensor terminated with a connector. The connector is, in turn, coupled to another connector or to a test and measurement instrument by wire, fiber optic, or other hardwired connection. In a measurement or control application of, for example, commercial and/or industrial processes, multiple sensors are typically attached by hardwired connections. Moreover, the extent and/or accuracy that a particular characteristic may be measured or controlled may be limited by a length or number of required connections in the communication path. In view thereof, it is advantageous to utilize multiple sensors without the drawbacks of multiple hardwired connections.
Accordingly, the inventors have realized that it is more desirable to employ wireless communication paths for providing information and data from a sensing device to process display, control and recording devices. Moreover, the inventors have realized that a wireless connector may also provide storage or logging features to further improve operation of the sensing device.
A wireless data logging module for a test and measuring device is presented. The data logging module provides improved functionality to the test and measuring device, which measures a variable of a process. The data logging module includes a wireless transceiver coupled to the test and measuring device. The wireless transceiver has a microprocessor for capturing and processing signals. The signals encode data and information including the measured variable from the test and measuring device. The transceiver also includes memory coupled to the microprocessor for storing the data, and communication circuitry coupled to the microprocessor. The communication circuitry includes input/output circuitry for transmitting and receiving the signals over a wireless communication path to a plurality of wireless devices.
In one embodiment, the test and measuring device includes a sensor for sensing the process variable. In one embodiment, the process variable includes at least one of temperature, voltage, humidity, pressure, strain, resistance, motion, light, current, velocity and flow.
In one embodiment, the wireless transceiver receives signals from at least one the plurality of wireless devices, processes the received signal and data and/or information encoded therein, and performs a predetermined response or directs the test and measuring device to perform a predetermined response.
The foregoing aspects and other features of the presently disclosed embodiments are explained in the following description, taken in connection with the accompanying drawings, wherein:
In these figures like structures are assigned like reference numerals, but may not be referenced in the description of all figures.
As shown in
Processing circuitry 136 may also be optionally provided within the chamber 106 of the wireless connector 100. The processing circuitry 136 may be implemented using hardware components, one or more processors running one or more programs, or a combination of both and may be re-programmable to perform any suitable processing operations. Communication circuitry 138 is included within the chamber 106 of the wireless connector 100 for transmitting signals provided by the sensor or signals output by the processing circuitry 136. In one embodiment, the communication circuitry 138 transmits signals. In another embodiment, the communication circuitry 138 includes transceiver circuitry for two-way wireless communication, e.g., both for transmitting data and information signals and for receiving data, information, command and control signals over the wireless communication path. For example, the communication circuitry 138 is capable of receiving command/control signals from a remote device and, optionally, in combination with the processing circuitry 136, performing received command/control actions or operations based on the received command/control signals. The communication circuitry 138 may also alter processing or communication operations based on the received command/control signals. In addition, the communication circuitry 138 may, optionally, in combination with the processing circuitry 136, be capable of transmitting command/control signals for controlling another device communicating with the wireless connector 100.
As described herein, the communication circuitry 138 provides wireless communication over the wireless communication path using any of a variety of different physical and protocol layer communication methods. For example, the communication technology may include optical, infrared, radio transmission, RFID, or any other suitable communication technology, and may incorporate IrDA, IEEE 802.11, 802.15, Bluetooth, PCS or any other suitable communication method or standard. For example, the ZigBee™ standard, based on IEEE 802.15, may also be utilized for its low power requirements, built in recognition capabilities, high reliability and relatively small packaging size (ZIGBEE is a registered trademark of ZigBee Alliance Corporation, San Ramon, Calif.). In an exemplary embodiment, the communication circuitry 138 is a ZigBee end device. In other exemplary embodiments, the communication circuitry 138 is a ZigBee coordinator or a ZigBee router.
In one embodiment, the processing circuitry 136 and the communication circuitry 138 are combined together as a single module. In one embodiment, the wireless connector 100 includes a power supply 140 disposed within the chamber 106 that includes one or more batteries for providing power to the processing circuitry 136, the communication circuitry 138, the sensor, or any other function or component requiring power. In one embodiment, an optional emitting device 145 is connected to the communication circuitry 138 to extend the range of communication, for example, to extend the wireless communication path. The emitting device 145 is included within the chamber 106 and extends through the wall 128 of the wireless connector 100 as shown, or may be enclosed by the wireless connector 100. In exemplary embodiments, the emitting device 145 may be, for example, an antenna, an optical emitter, or any other suitable emitting device. The wireless connector 100 may optionally have various indicators and controls such as a battery status indicator 150, a transmit/receive indicator 155, an on/off switch 160, adjustable components and additional switches 165 for calibration and for controlling the processing circuitry 136, the communication circuitry 138, and a display 170. The indicators and controls being accessible by, for example, holes or cutouts in the first cover portion 110.
In exemplary embodiments, when assembled, the wireless connector 100 may have a form factor similar to a ceramic, or miniature ceramic thermocouple connector body such as, for example, is sold by the assignee of the present application, Omega Engineering, Inc. (Stamford, Conn.), under a UWTC series of product models. While the processing circuitry 136, the communication circuitry 138, the emitting device 145, the various indicators and controls, and the power supply 140 are shown as having a particular size and shape, it should be understood that they may have any suitable size and shape, may be miniaturized, may be arranged together in various combinations, and may be combined in a single package or device.
The microprocessor 220 monitors and controls the communication circuitry 138 through the interface 240. For example, the microprocessor 220 instructs the communication circuitry 138 to establish communication over the communication path 101 with another device. The microprocessor 220 provides the communication circuitry 138 with data and/or information 202, e.g., derived from the signals 201 of the sensor 200 or processed signals from the signal processor 230, and instructs the communication circuitry 138 to transmit the data and/or information 202 over the wireless communication path 101, for example, on a periodic basis. In the event that communication with the other device is lost, the microprocessor 220 may instruct the communication circuitry 138 to monitor the connection and to re-establish communication when the other device becomes available and to resume transmission of the data and/or information 202.
The microprocessor 220 may also operate to store the data and/or information 202 derived from the signals 201 received from the sensor 200 or processed signals from the signal processor 230. For example, the signals 201 including the data and/or information 202 from the sensor 200 and/or from the signal processor 230, may be accumulated and stored in the memory 225 for transmission at a later time period. In one embodiment, the signals 201 including the data and/or information 202 are accumulated, stored in the memory 225, and then transmitted when instructed by the microprocessor 220, for example, in response to an event, on a particular date/time, or in response to a switch closure or a command received through the communication circuitry 138. Using the example above, the data and/or information 202 derived from the signals 201 of the sensor 200 may be accumulated and stored in the memory 225 during periods of lost communication and then sent when communication is re-established.
In exemplary embodiments, the microprocessor 220 or the signal processor 230, alone or in combination, process, modify or condition the signals 201 from the sensor 200. For example, microprocessor 220 or signal processor 230 may filter, amplify, compress, apply various algorithms or functions, or otherwise manipulate or clarify the signals 201 from the sensor 200. As another example microprocessor 220 or signal processor 230, alone or in combination, may process, modify or condition the signals 201 from the sensor 200 to accommodate characteristics of a device receiving the transmitted data. The processed, modified or conditioned signals may be transmitted upon receipt or stored and transmitted at a predetermined time (e.g., with a delay) as described above, e.g., over the wireless communication path 101. The microprocessor 220 and the signal processor 230 may also provide other types of data and/or information for transmission, or storage and transmission. For example, test or measurement time stamps may be included in the signals 201 from the sensor 200, a connector serial number or like identification information, a functional state or status of the connector 100 derived from running diagnostic functions, power supply information, location in real time, and the like. Moreover, the data and/or information 202 transmitted may include parity bits or like measures for ensuring complete point-to-point transmission. The data and/or information 202 transmitted may also employ security protocols including encryption and the like to provide secure transmission.
In one embodiment, the sensor 200 is a transducer capable of converting a measurable process characteristic to a signal for use by the wireless connector 100. For example, the sensor 200 may include a measurement device for sensing pressure, temperature, humidity, gas, pH, infrared, ultraviolet, visible light, voltage, current, power, conductivity, strain, load or acceleration. In an example where the sensor 200 is a thermocouple, such as a type-K thermocouple, the microprocessor 220 or the signal processor 230, alone or in combination, process, modify or condition the signals 201 from sensor 200 to appear as another type of thermocouple such as, for example, a type-J thermocouple while maintaining temperature accuracy. As a result, a J-type receiving device, such as a panel meter may display the proper temperature regardless of the type of thermocouple used to collect the temperature data. Thus, different types of sensors may be used as measuring devices for different types of receiving devices and instruments.
Returning to
The data communication circuitry 415 may also manage communication among a plurality of wireless connectors (e.g., the wireless connectors 100 and 300 as described below) by independently recognizing each of the plurality of connectors as they communicate, and assigning each of the plurality of connectors different communication channels, for example, different frequencies, time slots, chipping codes, or other differentiating communication characteristics. The second connector 410 may optionally include an external emitting device 430. The second connector 410 may also communicate with the connector 300 or multiple connectors 100 and 300. In an exemplary embodiment data communication circuitry 415 may be a ZigBee coordinator or a ZigBee router.
In one embodiment, the second connector 410 includes a power supply, for example, a battery for supplying power to data communication circuitry 415. Similar to disclosed embodiments of the connectors 100 and 300, in one embodiment the second connector 410 may have a form factor similar to a ceramic or miniature thermocouple connector body. The second connector 410 may also have male connector pins 420, 425 with cylindrical or blade shaped extending contacts.
The second connector 410 may plug into an instrument, meter, or other suitable equipment (described below) and provide signals from the sensor 200 to the equipment. Thus, the signals 201 from the sensor 200 may be provided without a hardwired connection between the sensor 200, the connectors 100, 300 and 410, and the test and measurement equipment.
In one embodiment, the equipment 510 includes test and measurement capabilities. For example, the equipment 510 may be any one or any combination of a meter, test equipment or a control device for processing pressure, temperature, humidity, gas, pH, infrared, ultraviolet, visible light, voltage, current, power, conductivity, strain, or acceleration. As described herein, the signals 201 from the sensor 200 may be provided without a hardwired connection between the sensor 200 and the equipment 510 such as by being transmitted over the wireless communication path 501. The equipment 510 may also communicate over a second wireless communication path 301 with the connector 300 having a built in sensor (e.g., the sensor 310) as described above. The equipment 510 may include circuitry 520 for driving a display 525 to present data and information (e.g., the data and/or information 202) related to the received signal in human readable form. The equipment 510 may also include processing circuitry 530 for further conditioning the received signal and process control circuitry 535 for controlling an external process or product, shown generally at 540, using the received signal or an output of the processing circuitry 530.
Other embodiments of the wireless connector 100 may be included as part of a thermocouple assembly, imbedded into a thermocouple head and well assembly, or into a thermocouple package or housing. The wireless connector 100 may be connected to thermocouple assemblies, pressure transducers, load cells, anemometers, and other sensors, as well as RTDs and thermistors. Alternately, the components of the wireless connector 100 may be incorporated into these and other types of assemblies.
In one aspect of the invention, illustrated in
In one embodiment, illustrated in
As shown in
The universal wireless transceiver 600 includes the power regulator circuitry 604 disposed on the base 602 for delivering electrical power to components of the universal wireless transceiver 600. In one embodiment, the power regulator circuitry 604 includes an internal power supply such as, for example, a battery. In another embodiment, power regulator circuitry 604 requires no internal power supply (e.g., battery) and instead receives electrical power from a host instrument (e.g., the test and measurement device 650) or is coupled to an external power source by means of an adapter. Accordingly, the universal wireless transceiver 600 is a self contained wireless device that may be mounted to an existing non-wireless test and measurement device or instrument. By coupling the universal wireless transceiver 600 to the existing device or instrument allows the instrument to receive wireless data and information (e.g., measurements of process variables) from a wide selection of sensors such as, for example, temperature, voltage, humidity, pressure, strain, resistance, motion, light, current, air velocity and flow measuring devices. For example, the universal wireless transceiver 600 receives data and information (e.g., the data and information 202) over the wireless communication path 601, processes the measurement data and information (e.g., with microprocessor 606), for example, converts the measurement data and/or information to an analog or digital output signal that is then feed or provided to the input/output connections 652 of the test and measurement device 650.
It should be appreciated that similar to the data communication circuitry 415 and 515 described above, the communication circuitry 608 of the universal wireless transceiver 600 manages communication from a plurality of sensors and/or wireless connectors (e.g., the wireless connectors 100 and 300) by individually recognizing the sensors and/or connectors and assigning them different communication channels in the wireless communication path 601, for example, different frequencies, time slots, chipping codes, or other differentiating communication characteristics. For example, in one embodiment, the communication circuitry 608 may include a ZigBee coordinator or a ZigBee router. In one embodiment, the communication circuitry 608 employs automatic communication channel switching (e.g., RF channel switching) to minimize or eliminate interference from other wireless communication devices.
In one embodiment, illustrated in
In one embodiment, the wireless transceiver 700 includes systems and methods for recording and storing data measured by a host sensor or instrument, process display or control device such as the handheld device 800. In this embodiment, for example, the transceiver 700 includes logging features as described below. The transceiver 700 comprises an input circuit 708 for receiving analog, digital or wireless information from the host sensor or instrument, a micro processor (e.g., micro processor 606) for measuring and processing the incoming data, a memory storage device 712 for saving the recorded data for later retrieval. Stored data can be retrieved by means of a hard wired connection to the module like via a USB connection or the module may incorporate a built-in radio transmitter for down loading recorded data wirelessly to a receiving instrument, printer or computer.
In one embodiment, the wireless transceiver and data logging module 700 is a stand-alone, self contained device that is directly attached to a sensor or host instrument, for example, the test and measurement device 800 of
It should be appreciated that any process can be measured and recorded by the wireless transceiver and data logging module 700 such as, for example, temperature, pressure, humidity, air speed, voltage, current, and the like. The recorded measurements are stored in the memory 712 of the module 700 for later retrieval and documentation. In one embodiment, the module 700 includes a removable memory card that can be directly inserted into a computer, PDA or cell phone for data transfer.
Thus, the disclosed embodiments provide a mechanism to utilize multiple sensors for monitoring and control a process without the drawbacks of installing and maintaining multiple hardwired connections. Moreover, the disclosed embodiments teach systems and methods for converting existing systems using test and measurement equipment hardwired to sensors, into systems that use test and measurement equipment that is coupled to sensors by wireless communication connections and which include data capture and logging features. Accordingly, the disclosed embodiments generally eliminate the need for wired connections from and between sensors and test and measurement devices and controllers.
It should be understood that the foregoing description is only illustrative of the present embodiments. Various alternatives and modifications can be devised by those skilled in the art without departing from the embodiments disclosed herein. Accordingly, the embodiments are intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
This patent application claims priority benefit under 35 U.S.C. §119(e) of copending, U.S. Provisional Patent Application Ser. No. 61/278,785, filed Oct. 10, 2009. This application is also related to U.S. patent application Ser. No. 12/470,969, filed May 22, 2009, which claims the benefit of U.S. patent application Ser. No. 11/877,285, filed Oct. 24, 2006. The disclosures of these U.S. patent documents are incorporated by reference herein in their entireties.
Number | Date | Country | |
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61278785 | Oct 2009 | US |