Patent Application
20110140908
Disclosed embodiments relate generally to control or monitoring systems, and more specifically to sensing systems and methods of wireless monitoring or control.
Processing facilities, such as manufacturing plants, chemical plants and oil refineries, are typically managed using process control systems. Valves, pumps, motors, heating/cooling devices, and other industrial equipment typically perform actions needed to process materials in the processing facilities. Among other functions, the process control systems often manage the use of the industrial equipment in the processing facilities.
In conventional process control systems, controllers are often used to control the operation of the equipment in the processing facilities. The controllers typically monitor the operation of the industrial equipment and/or the products or related materials through use of various sensors, and provide control signals to the equipment based on information retrieved from the various sensors. Wireless transmitters can be used with the sensors to provide data from the processing facility to a remotely located processor for evaluation of the data. The wireless transmitters are generally rigidly connected to various processing devices. In some arrangements (e.g., structures and the like in the path of transmission) or environmental conditions, for a given transmitted power level the signal strength of the data signal received at the processor or other remote receiver can be insufficient for accurate evaluation of the data required for proper control. Moreover, in certain applications, such as battery powered sensor arrangements, it may not be possible to increase the transmitted power level to compensate for poor received signal strength.
Disclosed embodiments described herein include wireless valve-position monitors that comprise a housing comprising a plurality of possible antenna module mounting ports. In contrast, conventional wireless valve-position monitors comprise a single antenna module mounting port that fixes the location of the antenna relative to the housing. A position sensor is within the housing that interfaces to a movable portion of a process-control valve for providing a position detection signal that reflects a current position of the process-control valve. A wireless transmitter comprising a transceiver coupled to an antenna module is coupled to the position sensor for transmitting a wireless signal that communicates the position of the process-control valve, such as to a network. The antenna module may be mounted to one of the plurality of possible mounting ports which allows a user the ability to select from multiple different antenna mounting locations, such as to provide improved communications (e.g., higher received signal levels) with a remote location. Moreover, the ability to select from multiple different antenna mounting locations allows antenna module location flexibility that enables use in applications that are not possible with conventional valve-position monitors in which a portion of the valve to be measured occupies the same space as the sole antenna module mounting location provided.
Disclosed embodiments are described with reference to the attached figures, wherein like reference numerals are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale and they are provided merely to illustrate the disclosed embodiments. Several aspects disclosed herein are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the disclosed embodiments and their equivalents. One having ordinary skill in the relevant art, however, will readily recognize that the disclosed embodiments can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring aspects of the disclosed embodiments. Disclosed embodiments are not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the disclosed embodiments of their equivalents.
Housing 110 is shown including a cover lock 119 coupled to a removable cover 127 that allows access to housing 110, such as to change the battery (e.g., lithium battery) 150 that is within the housing 110. As shown in
The position sensor 115 can comprise various sensor types, such as an optically-based sensor, a potentiometer, a variable capacitor, or a magnetoresistive (MR) sensor. The MR sensor embodiment affixes a target magnet to the valve stem and the MR sensor measures the angular position of the valve stem by measuring the changing magnetic flux of the target magnet while the target magnet is rotating. MR sensors can comprise magneto-resistive (GMR) sensors, anisotropic magneto-resistive (AMR) sensors, colossal magnetoresistive sensors or tunneling magnetoresistive sensors that are generally configured as Wheatstone bridge circuits.
A processor (e.g., a microprocessor or microcontroller) 118 is coupled to the output of the position sensor 115. The processor 118 is shown coupled to transceiver 135. The transceiver 135 typically includes a transmitter circuit and a receiver circuit which cooperate to transmit and receive radio signals to and from a remote location via antenna 125.
A wireless transceiver system as used herein comprises the transceiver 135 together with the antenna module 120. The antenna module 120 comprises conductors 121(a) and 121(b) that are coupled to an antenna element 125, wherein the antenna module 120 is mounted to one of the plurality of possible mounting ports on the housing 110, shown in
The antenna module 120 is shown including a connector 160 that mates with the plurality of possible antenna mounting ports connected to antenna module mounting port 111(a), such as by including coaxial boring and threading to mate with the threading 112 associated with antenna module mounting port 111(b) shown in
Antenna 125 is coupled to a distal end of conductor 121(b) and while transmitting transmits the wireless signal 130 shown in
The connector 160 is generally configured to permit the antenna module 120 and thus antenna 125 to be rotated with respect to the housing 110, such as rotated to identify an orientation that maximizes a receive signal strength at a remote location, for example, a network. A variety of rotatable connections may be used, such as the rotatable connection disclosed in U.S. Pat. No. 7,595,763 to Hershey, et al. assigned to Honeywell International.
The antenna module 120 can include one or more visual indicators 155 (LEDs for example) that illustrate a given state, change in state, or alert. Such indicators 155 can be displayed continuously, at given time intervals (programmed or preset), or conditionally activated through an electronics command (e.g., given wireless or through physical electronic signal). One use for visual indicators 155 is to indicate the signal strength of the received transmission at a remote location such as a network to allow an installer of wireless valve-position monitor 100 to identify the best mounting location and optionally the best orientation of the antenna module 120 for signal strength.
A sealing cap 140 may be placed over the antenna module mounting port(s) that are not in current use, such as antenna module mounting port 111(b) shown in
In another disclosed embodiment shown in
Disclosed wireless valve-position monitor can be installed on valves, such as a ball valve, even while the valve is currently in service. One attachment comprises a supporting element is attached to the body of the ball valve by one or more fasteners, such as screws. The supporting element is positioned so that the operation of the valve is not affected. As described below, in a typical application, a plurality of wireless valve-position monitor are installed on valves within a process facility to form a network. Each wireless valve-position monitor communicates with one or more central units and optionally other devices, or using a suitable wireless protocol.
The controlled valve-comprising system 400 is shown including a controller 415 that makes use of computing technology, such as a desktop computer or scalable server, for controlling operations of the controlled valve-comprising system 400 with respect to one or more process facilities 425 (only one shown). The controller 415 can allow for operator access to the controlled valve-comprising system 400, including operator intervention when desired. The controlled valve-comprising system 400 can also include a communications interface 430 that can utilize common technology for communicating, such as over a network 475, with a server 480.
The monitoring system 400 can further include a memory 465 (such as a high capacity storage medium) embodied in this illustration as a database 465. The network 475 can be various types and combinations of networks, such as wired and/or wireless networks, including a Local Area Network (LAN). The server 480 can be a client's device, such as a customer premises device, having a wireless communications device 410 (e.g., transmitter, receiver, or transceiver) allowing wireless communication with one or more wireless valve-position monitors 100 comprising transmitters, receivers or transceivers of the process facility 425 using various wireless protocols, such as Radio Frequency (RF) transmissions, IR transmissions, Wireless Fidelity (WiFi), Worldwide Interoperability for Microwave Access (WiMAX), Ultra Wide Band (UWB), software defined radio (SDR), cellular access technologies including CDMA-1X, W-CDMA/HSDPA, UMTS, GSM/GPRS, TDMA/EDGE, FDMA, DSSS, FHSS and EVDO, and cordless phone technology (e.g., DECT), BLUETOOTH™.
Wireless valve-position monitors 100(a) and 100(b) can be used to transmit sensor data to a remotely located receiver and receive data from a remotely located transmitting device, such as wireless communications device 410. By mounting antenna module 120 to the particular one of the plurality of antenna mounting ports provided allows controlled valve-comprising system 400 to operate with improved signal strength as compared to conventional controlled valve-comprising systems that provide a single antenna mounting port. Thus, disclosed wireless valve-position monitors can increase the transmitted signal strength (to some remote receiver), and also the received signal strength at the wireless valve-position monitor.
In one embodiment, the controlled valve-comprising system 400 can operate as a distributed control system (DCS) conforming in part to protocols defined by standards bodies, such as the OPC. In another embodiment, the controller 415 can operate utilizing a broad range of client, server and redundancy OPC technologies.
In yet another embodiment, the controller 415 can include an EXPERION™. Process Knowledge System (PKS) that utilizes OPC standards to provide data from the data source and communicates the data to any client application in a standard way, thereby eliminating the requirement for an application to have specific knowledge about a particular data source, such as its internal structure and communications protocols.
A method of process control using at least one wireless valve-position monitor comprising a housing having a plurality of possible antenna module mounting ports including a first and at least a second mounting port is now disclosed. A position sensor is within the housing that interfaces to a movable portion of a valve for providing a position detection signal that reflects a position of said valve, and a wireless transceiver system comprising a transceiver is coupled to an antenna module that is coupled to the position sensor for transmitting a wireless signal that communicates the position of the valve to a wireless communications device coupled to a controller remotely positioned from the wireless valve-position monitor.
A first signal strength of the wireless signal is measured at the wireless communications device while the antenna module is mounted to the first mounting port. The antenna module is removed from the first mounting port and is then mounted in the second mounting port. A second signal strength of the wireless signal is measured while the antenna module is mounted to the second mounting port. It is then determined which of the plurality of different antenna mounting locations to mount the antenna module from the first and second signal strength. The antenna module can further comprise at least one visual indicator, and the visual indicator can be used to provide an indication of the first and said second signal strength.
In order to facilitate installation of disclosed wireless valve-position monitors, in one embodiment the antenna module can include an RF coaxial cable and connector having a conduit hole. The antenna module could then be physically installed on any of the plurality of antenna mount locations with the coaxial cable protruding into the conduit hole. The conduit hole can be configured such that it would extinguish any flame internal to the cavity prior to an escape through the thread path. The coaxial cable could then be connected either directly to the radio transmitter or to an intermediary junction mounted on a bulkhead (or similar) that facilitates the connection to transmitter and the antenna (i.e. a bulk mount connector).
Disclosed valve position sensors can be used in a wide variety of applications to monitor the position of valves, and can send sensing wireless signals from remote or potentially dangerous areas of the process facility, such as a plant. The sensing signal can carry appropriate hazardous location certifications, which makes disclosed valve position sensors ideal for various applications such as monitoring valve positioner status, manual process valve position, safety shower and eye bath notification, tank overflow alarms, damper and louver position, door/gate position, or other applications where installing wires is inefficient, cost-prohibitive, or simply unsafe.
While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the disclosed embodiments. Thus, the breadth and scope of the disclosed embodiments should not be limited by any of the above explicitly described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.
Although the disclosed embodiments have been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting to embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the following claims.
