CN100472575C - 具有环超控的过程设备 - Google Patents
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- G01R19/25—Arrangements for measuring currents or voltages or for indicating presence or sign thereof using digital measurement techniques
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Abstract
本发明一种供过程控制系统之用的过程设备(12),包括被配置成耦合到过程控制环(18)的输出电路(60)。输出电路控制流过环(18)的电流。环超控电路(62)被配置成超控输出电路(60)的操作,并将环(18)中的电流设置为期望电平。
Description
技术领域
本发明涉及工业过程用类型的过程设备。尤其是,本发明涉及控制这种过程设备的过程控制环中电流的设备。
背景技术
如过程控制器、监视器和发送器的现场设备用于过程控制工业中,以便远程控制、监视和感测过程变量。例如,可以通过发送器将过程变量发送到控制室,供控制过程之用、或用于向控制器提供过程操作有关信息。例如,可以把与过程流体压力相关的信息发送到控制室,并用来控制诸如炼油的过程。
发送信息的一种典型现有技术涉及控制流过过程控制环的功率量。控制室中的电流源供给电流,并且发送器从其现场位置控制电流。例如,4mA信号可以用于指示0读数,而20mA信号可以用于指示满刻度读数。最近,发送器使用了数字电路,该数字电路利用被叠加到流过过程控制环的模拟电流信号上的数字信号,来与控制室进行通信。这种技术的一个例子是Rosemount公司所研制的通信协议。协议和其它这种协议典型地包括一组命令或指令,这组命令或指令可以被发送给发送器,以引出期望的响应,如发送器控制或询问。
Fieldbus(现场总线)是由现场总线基金会(Fieldbus Foundation)提出的一种通信协议,它旨在定义一种用于在过程控制环上发送信息的通信层或协议。在Fieldbus协议中,流过环的电流不用于发送模拟信号。而是,通过调制过程控制环中流动的电流,来数字发送所有信息。进一步,Fieldbus标准和被称为Profibus的标准,允许以多个发送器耦合到同一过程控制环上的多分支结构来配置发送器。其它通信协议包括协议和以太网。在某些结构中,两条、三条、四条或任何数量的线可用于耦合到过程设备,包括非物理耦合如射频(RF)。
一些过程发送器也能够发送报警信号,该报警信号可以提供过程变量测量饱和了(即过程扰乱)的指示。一种类型的报警信号将流过环的电流固定在预定电平处或预定阈值以外。例如,一种类型的报警信号是大于21mA或小于3.8mA的电流电平,它们分别可用于发送“高报警”或“低报警”。一旦报警条件发生,就可以通过发送器发送报警信号。
发明内容
一种供过程控制系统之用的设备包括被配置成耦合到过程控制环、且控制流过环的电流的输出电路。环超控电路(loop overridecircuity)被配置成超控(override)输出电路的操作,并将环中电流设置为期望电平。
附图说明
图1示出了包括耦合到过程控制环的过程设备的过程控制系统。
图2是示出图1过程设备的内部的透视图。
图3是该过程设备中电路的简化框图。
图4是包括用于实现诊断电路的比较器的电路的简化框图。
图5是包括用于实现诊断电路的模数转换器的电路的简化框图。
图6A是示出环超控电路和输出电路并联的简化电路图。
图6B是示出环超控电路和输出电路串联的简化电路图。
图7是图1过程设备中的电路的更详细框图。
具体实施方式
本发明提供一种被配置成超控过程设备中输出电路的操作的环超控电路(loop override circuity)。可以在用于控制过程控制环中的电流、并且不限于在此讨论的说明性过程设备的任何过程设备中,实施本发明。例如,在此描述的一种过程设备是包括用于感测过程变量的传感器的发送器。然而,过程设备不必感测过程变量来实现本发明的各个方面。甚至一旦过程设备中的其它电路发生故障,环超控电路就能够在过程控制环上发送报警信号(或其它信号)。这允许设备发送否则可能检测不到(突然出现)的报警信号。在另一实施例中,提供一种检测设备控制环电流的能力的丢失的技术。
图1示出了包括耦合到过程管道16的发送器12的过程控制系统10。发送器12耦合到按照FOUNDATIONTM Fieldbus(现场总线)、Profibus或标准操作的双线过程控制环18。然而,本发明不限于这些标准或双线配置。双线过程控制环18在发送器12和控制室20之间运行。在环18按照协议操作的实施例中,环18能够传送代表所感测的过程变量的电流I。另外,协议允许将数字信号叠加在流过环18的电流上,以至可以将数字信息发送给发送器12或者从发送器12接收数字信息。当按照Fieldbus标准操作时,环18传送数字信号,并且可以耦合到多个现场设备如其它发送器。
图2是发送器12的透视图,它示出了发送器12中装有的电路块的一种范例配置。在该范例实施例中,发送器12包括耦合到感测模块42的特征模块40。感测模块42通过歧管过程耦合(manifold process coupling)44而耦合到过程管道16(图1所示)。
特征模块40包括特征模块电子电路50,该特征模块电子电路50耦合到感测模块42中装有的感测模块电子电路52。典型地,感测模块电子电路52耦合到用于感测与过程操作相关的过程变量的过程变量传感器,例如图1所示的传感器21。特征模块电子电路50包括输出电路60、环超控电路62和诊断电路64。电路60、62和64可以用硬件、软件或硬件和软件混合组合的形式来实现,并且可以位于发送器12内的任何地方。
在操作期间,输出电路60控制流过环18、且代表例如被测过程变量的电流I的值。这可用于监测或控制工业过程的操作。在某些应用中,输出电路60也用于向发送器12内的电路提供功率,该功率是利用通过环18接收的功率来产生的。在某些应用中,如获得SIL(安全完善度等级)认证的应用中,发送器12必需满足某些可靠性准则。例如,为了确保一旦发生故障或即将发生故障、过程就被关闭,某些认证要求适当地发送报警信号,使得即使发送器12中某些部件发生了故障,安全关闭也能够发生。
根据本发明一个方面,诊断电路64可以提供诊断,该诊断用于检测发送器12的内部故障模式和/或外部影响如短缺(starvation)或电磁干扰(EMI),这将在后面描述。诊断电路64能够检测输出电路60的故障或即将发生的故障。诊断电路64用于激活环超控电路62,环超控电路62超控输出电路60的操作,并在环18上设置报警电流电平。例如,环超控电路62可以将环电流设置为预定值。在4—20mA电流环中,可以通过环超控电路62将电流I设置为小于3.8mA或大于21mA的值,由此在环18上发送报警信号。这些电流电平分别被称为“低报警”和“高报警”。然而,可以随意将电流设置为任何电平,包括设置为代表过程变量的电平。
图3是发送器12的简化框图。如图3所示,发送器12包括耦合到过程变量传感器21的测量电路70。可以将电路70包括在图2所示的传感器模块电路52上。输出级72连接到测量电路70,并被配置用于在过程控制环18上发送(以及在某些实施例中接收)信息。输出级72包括环超控电路62和输出电路60。然而,可以根据其它实施例来配置电路60和62。测量电路70被配置成提供对传感器21所感测的过程变量的初始处理。测量电路70的实现经常包括微处理器。微处理器也可用于实现图3所示的其它电路功能性。
在正常操作期间,传感器21所感测的过程变量被转换成模拟电流电平或数字信号,以便利用输出电路60在过程控制环18上传输。然而,当通过诊断电路64感测到报警条件时,环超控电路62被配置成超控输出电路60所产生的输出,并将环18中传送的电流电平I驱动到预定报警电平,例如预定阈值电平之上或之下。环超控电路62可以和输出电路60串联或并联,或者可以被包括在电路60中。也可以使用其它配置。在某些实施例中,环超控电路62被配置成切断或者相反断开输出电路或发送器12中的其它部件。
诊断电路64能够感测如用户所希望的报警条件。诊断电路64能够按照任何诊断技术进行操作,并且不限于在此具体阐述的诊断电路。例如,可以将诊断电路64配置成感测发送器12内单个部件或发送器12内所有部件的静态电流吸取(quiescent current draw)。通过静态“工作”电流电平的增大,可以识别许多故障机制的开始。在2003年8月7日提交的、题为“具有静态电流诊断的过程设备(PROCESS DEVICEWITH QUIESCENT CURRENT DIAGNOSTICS)”的美国专利申请No.10/635,944中,对此进行了描述。可以根据静态电流吸取检测到的范例故障包括:由于静电放电损害引起的潜在故障、由于闪电或瞬变电事件引起的部件损坏、如齐纳二极管的半导体的泄漏、滤波器元件如电容器的泄漏、由于枝晶(dendrite)生长或腐蚀引起的泄漏、或者其它故障或即将发生的故障。
静态电流诊断能力允许预测和检测由于静态电流增大而造成的不能控制过程环电流I,由此初始化环超控电路62。
静态电流诊断尤其有利于以诸如范例Fieldbus的数字格式独占通信的设备。在诸如这种设备上,如果静态电流电平阻止了数字信号的发送,则设备没有其它手段来发送过程相关信息。因此,利用这种静态电流诊断配置,发送器12能够在最终故障之前发送关于即将发生的故障的指示。在一个实施例中,环超控电路62能够使发送器12通信电路从过程控制环18断开。在另一个实施例中,当静态电流牵引达到了发送器12或过程控制环18将停止运行的电平时,环超控电路62能够使发送器12从过程控制环18断开,使得过程控制环18能够继续操作。
图4是示出诊断电路64一个实施例的简化框图。在图4中,比较器74用于感测和环电流I串联的电阻器76的电压降。比较器74可以被配置成检测超过预定阈值电平的环电流变化,并响应此而向环超控电路62提供信号。响应来自比较器74的信号,环超控电路62超控输出电路60的正常操作,并将环电流I驱动到报警电平。比较器74可以包括多个比较器,以便例如检测超过上阈值和下阈值的电流偏移。可以利用任何适当的手段,例如梯形电阻器网络、二极管或其它技术,来产生比较器74的基准输入。比较器74的输出被显示为耦合到环超控电路62。环超控电路62可以包括接收比较器74的输出的微处理器,或者比较器74的输出可以用于直接控制环超控电路62的电部件。
图5是示出本发明另一实施例的简图,其中诊断电路64是利用和电阻器76并联的模数转换器80来形成的。如上所讨论的,电阻器76和环18串联,以至电阻器76的电压降指示环电流I。模数转换器80的输出可以耦合到环超控电路62或图7所示的微处理器138。该微处理器对数字化环电流值和存储器中存储的阈值进行比较,并响应此而激活环超控电路62将环电流驱动到报警信号电平。阈值例如可以存储在存储器中。另外,诊断电路64可以监测环电流I,以检测环电流值的趋势。环电流趋势的失常,例如由于短缺或EMI引起的失常,可用于激活环超控电路62。如果端电压不足(短缺),则输出电路60可能不能获得期望输出。大电磁干扰电平的存在可能造成环电流I的偏移。在另一个例子中,微处理器可以对数字化环电流值和预期环电流值进行比较。例如,预期环电流值可以是应该为所感测的过程变量特殊值而设置的环电流值。如果所感测的环电流值与预期环电流值的差异超过预定量如某一百分数,则微处理器可以触发环超控电路62的操作。
图6A和6B是示出输出电路60和环超控电路62的范例配置的两个简化框图。在图6A中,环超控电路62和输出电路60并联。示出了环超控电路62和输出电路60之间的任选连接,在某些实施例中,该任选连接允许环超控电路62切断输出电路60、或者相反使输出电路60从环18断开。在图6B中,环超控电路62被显示为和输出电路60串联。环超控电路62和输出电路60之间的任选连接可用于使输出电路60从环18断开、或绕过输出电路60。也可以使用其它配置,如串—并联、或输出电路60和环超控电路62共享某些或全部部件的实施例。例如,可以利用一个或多个开关或保险丝,将设备从环电断开。
一旦通过诊断电路64检测到不能控制环电流,环超控电路62就用于确保发送器12输出有效报警信号。例如,当如图6A所示环超控电路62和输出电路60并联时,环超控电路62可以使附加电流分流,以至总环电流大于21mA,以指示高报警信号。在另一范例实施例中,环超控电路62包括断开机制,以至可以断开冒犯电路(offending circuit),由此允许通知高报警信号或低报警信号。在这种实施例中,断开电路可以和冒犯电路串联。在另一实施例中,环超控电路62可以包括第二(或备用)环控制电路,如果希望的话,该第二环控制电路可用于控制环电流。在另一范例实施例中,诊断电路64包括看门狗电路150,该看门狗电路150必须由微处理器或发送器12中的其它装置来周期地触发。看门狗电路150可以检测包括硬件或软件故障的故障。如果看门狗电路150没有在预置时限内被触发,则可以激活环超控电路62,由此发送高或低报警信号。
图7是示出发送器12中电路的一个例子的更详细框图。在图7中,特征模块电子电路50被显示为通过并联调节器100和环读回电阻器104耦合到双线过程控制环18。功率调节器110耦合到传感器模块电子电路52。传感器模块电子电路52也被显示为通过过程变量传感器112耦合到过程。还显示了任选的输出显示器114。
环超控电路62可以部分地在耦合到数模(D/A)转换器122和模数(A/D)转换器64的微控制器138中被实现。模数转换器64被配置成测量环电流,并且也可实现诊断电路64的功能性。
在操作中,微控制器138被配置成,利用数模转换器122和并联调节器100来控制通过环18的电流I、以及被调制到该电流I上的任何数字数据。模数转换器64提供一种指示流过环18的电流I的输出。模数转换器64也可以被耦合成提供与发送器12或发送器12中部件所吸取的静态(工作)电流相关的输出。微控制器138包括存储器140,该存储器140可以包含用于检测报警条件中的阈值。通过根据被感测过程变量周期地对所测量的环电流和存储器140中存储的阈值或环电流预期值进行比较,微控制器138可以确定报警条件是否发生。当然,可以随意检测其它报警条件,并且本发明不限于在此阐述的报警条件。
一旦检测到报警条件,微控制器138就通过激活环超控电路62来在过程控制环18上发送报警信号。然后,流过环18的电流I被设置为固定电流电平。在某些实施例中,可以断开或切断设备中的电路,以便向其它电路提供足够的功率来提供期望输出。提供环超控的一种技术是断开设备,或者相反使设备脱离过程控制环。
图7也显示了耦合到微控制器138的看门狗电路150。看门狗电路150必须由微控制器138周期地触发。如果微控制器138停止触发看门狗电路150,则可以假定故障发生了。范例包括但不限于:不适当的程序流、微处理器或存储器故障、时钟错误等。如果看门狗电路150未被触发,则看门狗电路150向环超控电路62发送信号,以使环超控电路62在过程控制环18上驱动报警电流电平。
虽然参考优选实施例描述了本发明,但是本领域工作人员将认识到,在不脱离本发明精神和范围的情况下,可以在形式和细节上进行改变。以上描述用一种范例配置说明了本发明,并且可以使用任何适当的过程控制环,如4—20mA、2、3或4线环,多分支环,以及按照Fieldbus、Profibus、或其它通过控制过程控制环中电流来发送过程相关信息的通信协议进行操作的环。本发明在向过程控制环提供附加安全层的安全仪表系统(SIS)配置中尤其有用。本发明可以提供一种提高过程设备的SIL等级的技术。这些技术可以用于将未检测到的故障或潜在的不安全条件转换成根据安全条件来发生的被检测到故障,由此提高SIS中使用的过程设备的安全故障率(SFF)。本发明可以和2003年11月21日提交的、题为“具有监督上层的过程设备(PROCESS DEVICE WITH SUPERVISORY OVERLAYER)”的美国申请No.10/________中所阐述的技术一起使用。
Claims (50)
1.一种供过程控制系统之用的过程设备,包括:
输出电路,该输出电路被配置成耦合到过程控制环,并控制流过环的电流以发送过程相关信息;以及
环超控电路,该环超控电路独立于输出电路,并被配置成针对输出电路对流过环的电流的控制而进行超控,并将流过环的电流设置为期望电流电平。
2.根据权利要求1所述的设备,包括:诊断电路,该诊断电路被配置成检测报警条件,并响应此而启动环超控电路。
3.根据权利要求2所述的设备,其中诊断电路测量静态电流电平。
4.根据权利要求2所述的设备,其中诊断电路包括:和环串联的感测电阻器。
5.根据权利要求2所述的设备,其中诊断电路包括:模数转换器。
6.根据权利要求2所述的设备,其中诊断电路监测电流的趋势。
7.根据权利要求2所述的设备,其中诊断电路包括:微控制器。
8.根据权利要求1所述的设备,其中过程设备是过程变量发送器。
9.根据权利要求1所述的设备,其中过程设备是过程控制器。
10.根据权利要求1所述的设备,其中过程设备被配置成供安全仪表系统之用。
11.根据权利要求1所述的设备,其中期望电流电平大于21mA或小于3.8mA。
12.根据权利要求1所述的设备,其中环超控电路包括:微控制器。
13.根据权利要求1所述的设备,其中完全利用通过过程控制环收到的功率来向过程设备供电。
15.根据权利要求1所述的设备,包括:比较器,该比较器被配置成如果环电流在预定阈值电平之外就启动环超控电路。
16.根据权利要求1所述的设备,其中环超控电路和输出电路并联。
17.根据权利要求1所述的设备,其中环超控电路和输出电路串联。
18.根据权利要求1所述的设备,其中环超控电路被配置成使输出电路从过程控制环断开。
19.根据权利要求1所述的设备,其中环超控电路被配置成使电流分流越过输出电路。
20.根据权利要求1所述的设备,包括:看门狗电路,该看门狗电路被配置成激活环超控电路。
21.根据权利要求1所述的设备,包括:微控制器,该微控制器被配置成激活环超控电路。
22.根据权利要求21所述的设备,其中微控制器根据环电流的趋势来激活环超控电路。
23.根据权利要求21所述的设备,其中微控制器根据环电流和环电流预期值的比较,来启动环超控电路。
24.根据权利要求1所述的设备,包括:被配置成断开过程设备内的电路的电路。
25.根据权利要求1所述的设备,其中环超控电路被配置成断开输出电路,并控制环电流电平。
26.根据权利要求25所述的设备,其中通过冗余输出电路来控制环电流电平。
27.根据权利要求1所述的设备,其中过程设备被配置成供安全仪表系统之用。
28.根据权利要求1所述的设备,其进一步包括:被配置成感测过程变量的传感器。
29.根据权利要求28所述的设备,其中过程设备是过程变量发送器。
31.根据权利要求1所述的设备,其中输出电路被配置成耦合到从包括双线、三线和四线的组中选择的过程控制环类型。
32.根据权利要求1所述的设备,其中环超控电路进一步被配置成使过程设备从过程控制环电断开。
33.一种在在过程控制环上发送期望电流信号的过程设备中实现的方法,包括:
使用耦合到过程控制环的设备中的输出电路,基于所感测的过程变量对过程控制环中的环电流进行控制;
检测耦合到过程控制环的过程设备中的报警条件;
响应于所检测到的报警条件,针对设备中的输出电路对环电流的控制而进行超控;以及
在超控期间,将环电流控制为期望电平。
34.根据权利要求33所述的方法,其中报警条件与静态电流吸取有关。
35.根据权利要求34所述的方法,其中检测包括:检测静态电流吸取的趋势。
36.根据权利要求33所述的方法,其中期望电流电平大于21mA或小于3.8mA。
37.根据权利要求33所述的方法,其中超控步骤是在微控制器中实施的。
38.根据权利要求33所述的方法,其中检测步骤是在微控制器中实施的。
39.根据权利要求33所述的方法,包括:完全利用通过过程控制环收到的功率来向过程设备供电。
41.根据权利要求33所述的方法,其中检测步骤包括:比较电流和预定阈值电平。
42.根据权利要求33所述的方法,其中超控步骤包括:使输出电路从过程控制环断开。
43.根据权利要求42所述的方法,进一步包括:利用冗余输出电路来控制环电流电平。
44.根据权利要求33所述的方法,其中控制步骤包括:使电流分流越过输出电路。
45.根据权利要求33所述的方法,其中检测步骤包括:监测环电流的趋势。
46.根据权利要求33所述的方法,其中检测步骤包括:比较环电流和环电流预期值。
47.一种用于实现权利要求33所述的方法的过程设备。
48.根据权利要求33所述的方法,进一步包括:感测过程变量。
50.权利要求33所述的方法,该方法在被配置成供安全仪表系统之用的设备中实施。
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-
2003
- 2003-08-07 US US10/635,944 patent/US7018800B2/en active Active
- 2003-12-11 US US10/733,558 patent/US7098798B2/en active Active
-
2004
- 2004-08-05 CN CN2004800295163A patent/CN1864071B/zh active Active
- 2004-08-05 DE DE602004029468T patent/DE602004029468D1/de active Active
- 2004-08-05 CN CNB2004800295159A patent/CN100472575C/zh active Active
- 2004-08-05 JP JP2006522716A patent/JP4762140B2/ja not_active Expired - Fee Related
- 2004-08-05 WO PCT/US2004/025291 patent/WO2005017544A1/en active Search and Examination
- 2004-08-05 RU RU2006106911/28A patent/RU2350975C2/ru not_active IP Right Cessation
- 2004-08-05 JP JP2006522718A patent/JP2007501980A/ja active Pending
- 2004-08-05 EP EP04757422A patent/EP1656564A1/en not_active Ceased
Also Published As
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DE602004029468D1 (zh) | 2010-11-18 |
WO2005017544A1 (en) | 2005-02-24 |
RU2350975C2 (ru) | 2009-03-27 |
CN1864183A (zh) | 2006-11-15 |
EP1656564A1 (en) | 2006-05-17 |
US20050030186A1 (en) | 2005-02-10 |
US7018800B2 (en) | 2006-03-28 |
US7098798B2 (en) | 2006-08-29 |
JP2007501979A (ja) | 2007-02-01 |
US20050030185A1 (en) | 2005-02-10 |
JP2007501980A (ja) | 2007-02-01 |
RU2006106911A (ru) | 2006-08-10 |
CN1864071A (zh) | 2006-11-15 |
CN1864071B (zh) | 2010-08-11 |
JP4762140B2 (ja) | 2011-08-31 |
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