CN102066880B - 用于现场设备的无线通信适配器 - Google Patents

用于现场设备的无线通信适配器 Download PDF

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CN102066880B
CN102066880B CN2009801226110A CN200980122611A CN102066880B CN 102066880 B CN102066880 B CN 102066880B CN 2009801226110 A CN2009801226110 A CN 2009801226110A CN 200980122611 A CN200980122611 A CN 200980122611A CN 102066880 B CN102066880 B CN 102066880B
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field apparatus
communication adapter
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wireless process
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乔尔·D·万德拉
克里斯蒂娜·A·格鲁尼克
罗纳德·F·赫德
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D11/00—Component parts of measuring arrangements not specially adapted for a specific variable
    • G01D11/24—Housings ; Casings for instruments
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    • G—PHYSICS
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    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
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    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
    • G—PHYSICS
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    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31121—Fielddevice, field controller, interface connected to fieldbus
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/33—Director till display
    • G05B2219/33192—Radio link, wireless
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    • G05B2219/34481—EFC explosion free control, intrinsically safe
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Abstract

提供了一种无线过程通信适配器(14，30)。适配器(14，30)包括具有多个开口(150，152)的壳体(120)。端盖(124)连接至所述多个开口(150，152)中的第一开口(150)。现场设备联接器(122)设置在所述多个开口(150，152)中的第二开口(152)处。壳体(120)、端盖(124)和现场设备联接器(122)在其中限定腔室(130)。至少一个电路板设置在该腔室(130)内，所述电路板(132，134)具有无线通信电路系统设置其上并能够通过现场设备联接器(122)连接至现场设备(12)。在一个方面中，基本上所述腔室内的所有剩余体积都用固体材料填充(136)。在另一方方面中，防爆屏障(164)设置在现场设备联接器(122)中。还提供了所述方面的组合。

Description

用于现场设备的无线通信适配器
背景技术
在工业设置中，控制系统用来监测和控制工业和化学过程等的物料量。典型地，控制系统采用分布在工业过程中的关键位置处且通过过程控制回路连接至控制室中的控制电路的现场设备执行这些功能。术语“现场设备”涉及任何在分布式控制或过程监控系统中执行一定功能的设备，包括所有目前已知的设备，或还不知道的设备，用在工业过程的测量、控制和监测中。
一些现场设备包括换能器。换能器被理解为是指基于物理输入产生输出信号或基于输入信号产生物理输出的装置。典型地，换能器将输入转换成具有不同形式的输出。换能器的类型包括各种分析设备、压力传感器、电热调节器、热电偶、应变仪、流量变送器、数字阀控制器、流量计、流量计算器、定位器、传动装置、螺线管、指示灯以及其它的。
典型地，每个现场设备还包括用于与过程控制室或过程控制回路上其它电路系统通信的通信电路系统。在一些装置中，过程控制回路还用来向现场设备传送调节电流和/或电压，用来向现场设备供电。过程控制回路还传递模拟或数字格式的数据。
传统上，模拟现场设备已经由二线过程控制电流回路连接至控制室，每个设备由单个二线控制回路连接至控制室。典型地，将所述二线之间的电压差维持为，对模拟模式在12-45伏的范围内，对数字模式在9-50伏的范围内。一些模拟现场设备通过将在电流回路上传播的电流调整为与所感测的过程变量成比例的电流而将信号传递至控制室。其它现场设备可以在控制室的控制下，通过控制所述回路上的电流大小执行动作。除此之外，或作为替换，过程控制回路还可以传输用于与现场设备通信的数字信号。
在一些装置中，无线技术已经开始用来与现场设备通信。无线操作简化了现场设备配线和配置。然而，现场设备的主要部分硬接接至过程控制室，并且不采用无线通信技术。
工业过程工厂通常包含数百甚至数千个现场设备。这些现场设备中的多个都包含复杂的电子组件，且能够提供比传统模拟4-20mA测量更多的数据。由于多个原因，它们中的成本，多数工程不利用可有由这种现场设备提供的其它数据。这形成了对用于这种现场设备的无线适配器的需求，这种适配器能够连接至现场设备并经由无线网络将数据传递回控制系统或其它监控或诊断系统或应用。
为了使工业过程工厂运转，现场设备通常必须带有危险位置允许等级(hazardous location approval rating)。具有不同类型的等级，为了广泛采用，无线现场设备适配器应当能够连接至每一个这种现场设备，而不牺牲该现场设备的危险位置允许等级。
这些允许等级中的一种熟知为防爆等级。防爆外壳的目的是遏制可燃气体进入外壳并燃烧产生的爆炸。如果外壳不能遏制这种爆炸，则它会点燃周围的其它，导致灾难性的后果。无线设备厂商面临的一个挑战是如何通过能够承受爆炸压力的外壳传播无线信。这种外壳通常很大，并由诸如钢或铝之类的金属制成。目前可用的无线传输技术包括厚的玻璃天线屏蔽罩或具有能量限制电路并与相对易碎的“橡胶帆布”天线装配在一起的防爆同轴引线。单独的塑料天线屏蔽罩不被相信能够承受爆炸压力，它们也不被相信满足批准机构的化学、环境和抗冲击要求。
另一种类型的允许等级熟知为本质安全(IS)。通过限制电子组件中存在的电流的量并通过确保电子元件隔开的足够远而防止在电故障情况下出现的电弧，本质安全设备防止可燃气体点燃。还控制由电子元件产生的热量。使设备的电子组件本质上安全倾向于增加元件数量以及增加电路板尺寸。在必须最小化设备的形状因素时，这也提出了挑战。
为了使无线通信适配器用在防爆设备中，它本身必须是防爆的，并且它在两个设备之间的连接处提供防爆屏障。对于本质安全装置，无线通信电路系统必须也是本质安全的。将这种适配器连接至任何设备的能力也推动了形状因素。工业设备，如现场设备，可以以多种结构安装，并且通常设置在狭窄的空间中。这需要小且不显眼的设计。为了实现这种设计，有利的是天线与无线通信适配器一体形成，电路板尺寸最小化。这使得装置的设计更复杂，要求防爆鉴定或本质安全鉴定。
为现场设备提供一种相对小且不显眼并且还能够便于符合防爆鉴定和本质安全的无线通信适配器将推动无线过程通信技术。
发明内容
提供了一种无线过程通信适配器。该适配器包括具有多个开口的壳体。端盖连接至所述多个开口中的第一开口。现场设备联接器设置在所述多个开口中的第二开口处。壳体、端盖和现场设备联接器在其中限定腔室。至少一个电路板设置在该腔室内，所述电路板具有无线通信电路系统设置在其中并能够通过现场设备联接器连接至现场设备。在一个方面中，基本上所述腔室内的所有剩余体积都用固体材料填充。在另一方方面中，防爆屏障设置在现场设备联接器中。还提供了所述方面的组合。
附图说明
图1为可操作地连接至根据本发明实施方式的无线通信适配器的过程有线现场设备的示意图。
图2示出了根据本发明实施方式的现场设备和无线过程通信适配器的简化剖视图。
图3为根据本发明实施方式的无线过程通信适配器的剖面示意图。
具体实施方式
本发明的实施方式大体上提供了一种无线变送器，其可以连接至为防爆的或本质安全的有线现场设备，而不损害这种现场设备的允许等级。无线通信适配器构造为提供爆炸保护，并且优选包含本质安全电子组件。该适配器优选包括在至有线设备的连接位置处的防爆屏障，并包括完全被包围的电子组件。
图1为可操作地连接至根据本发明实施方式的无线通信适配器14的过程有线现场设备12的示意图。虽然现场设备12在图1中图示为过程流体压力变送器，如从Minnesota州Chanhassen市的Emerson ProcessManagement公司可买到的以商品名模型3051S售卖的过程流体压力变送器，但可以使用任何适合的现场设备。典型地，现场设备包括传感器模块，如传感器模块16，和电子模块，如电子模块18。而且，如上所述，现场设备12通常设计为符合防爆规定。而且，现场设备12内的电子组件的设计可以与本质安全要求一致，如由Factory Mutual Research于1998年10月颁布的、名称为“APPROVAL STANDARD INTRINSCIALLY SAFEAPPARATUS AND ASSOCIATED APPARATUS FOR USE IN CLASS I，II，AND III，DIVISION 1 HAZARDOUS(CLAS SIFIED)LOCATIONS，CLASSNUMBER 3610”的标准中的一个或多个部分。现场设备12通常包括位于传感器模块16的传感器，如压力传感器，传感器模块16转换过程流体特性，如压力，并向电子模块18提供过程流体变量的电学表示。电子模块18随后在通常通过输入装置20耦接的过程通信回路传递过程变量信息。
如上所述，变得有利的是，向过程有线现场设备提供其它通信能力，如无线通信能力。通过提供无线过程通信适配器，如过程通信适配器14，可以传输通过过程有线连接传递的信息之外的其它数字信息。这种信息可以传递至单独的监控或诊断系统或应用，用于分析。而且，简单地设置其它通信资源，如适配器14，还允许冗余通信。对过程通信适配器14来说重要的是可连接至现场设备，而不会不利地影响组件的能力，以继续满足防爆和/或本质安全要求。
图2示出了根据本发明实施方式的现场设备12和无线过程通信适配器14的简化剖视图。现场设备12通过输入装置20和导管11连接至过程通信回路22。过程通信回路的例子包括高速可编程远程换能器(HART
Figure BPA00001277497200041
)协议和FOUNDATIONTM Fieldbus协议。然而，其它有线过程通信协议是已知的。在过程变量变送器的例子中，现场设备12包括过程变量传感器50，其连接至测量电路52，以测量过程变量。变送器电路54构造为接收过程变量并采用已知的技术在二线式过程控制回路22上传播过程变量。现场设备12通过端子板106连接至二线式过程控制回路22。无线通信适配器30通过端子板106连接至二线式过程控制回路22并且例如通过螺纹连接123和109安装至现场设备12的壳体。无线过程通信适配器30的底盘通过导线108连接至现场设备12的电接地连接器110。现场设备12包括二线式过程端子板102，其连接至来自无线过程通信适配器30的连接112。无线过程通信适配器30的壳体120带有连接至无线过程通信适配器30的无线通信电路系统的天线126。射频(RF)透明端盖124可以用来密封地连接至壳体120，以允许RF信号从中传输通过。在图2中示出的配置中，为射频适配器设置了五个电连接，包括四个回路连接以及一个电接地连接。
图3为根据本发明实施方式的无线过程通信适配器的剖面示意图。如图3所示，无线过程通信适配器优选包括圆筒形、金属外壳120，在一端具有用于容纳射频透明屏蔽罩或端盖124的大开口150，在另一端具有用于容纳现场设备联接器122的相对小的开口152。电子组件154位于优选在一对印刷电路板132、134的腔130内。电子组件优选包括无线通信电路系统，用于允许无线过程通信适配器根据一种或通过无线通信协议进行通信。适合的无线过程通信协议的例子包括：无线网络技术(如California州由Irvine市的Linksys搭建的IEEE 802.11b无线接入点和无线网络设备)；蜂窝或数字网络技术(如Califoruia州San Jose市的AerisCommunications公司的Microburst
Figure BPA00001277497200051
)；超宽带，自由空间光学，全球移动通信系统(GSM)，通用分组无线业务(GPRS)；码分多址(CDMA)；扩展频谱技术，红外通信技术；SMS(短消息业务/文本消息)；已知的蓝牙规范，如从Bluetooth SIG(www.bluetooth.com)可获得的蓝牙核心规范1.1版(2001年2月22日)；以及例如由Hart通信机构公布的无线HART
Figure BPA00001277497200052
规范。无线HART
Figure BPA00001277497200053
规范的相关部分包括：HCF_Spec 13，7.0版；HART规范65-无线物理层规范；HART规范75-TDMA数据链层规范(TDMA称为时分多址)；HART规范85-网络管理规范；HART规范155-无线命令规范；和HART规范290-无线设备规范。
每个电路板132、134上的电子组件优选安装为在它们附近有间隔，并位于电路板之间，以便于灌注成分的流动。在外壳密封的情况下，灌注料136通过通道156注入室130中，直到外壳变满。可以使用任何适合的灌注成分，但重要的是，灌注材料本身满足批准机构的要求，包括适合的耐化学性、热和冷操作温度下的热稳定性、以及其它相关参数。天线屏蔽罩124、外壳120和现场设备联接器122为灌注料136提供了挡风雨的壳体。
现场设备联接器122提供了直接连接至现场设备12的方法。馈通组件140优选还用作连接位置处的防爆屏障。如果可燃气体进入现场设备的外壳并点燃，馈通组件140将遏制爆炸。引线158、160穿过馈通组件140。联接器的内部填充有能够承受爆炸压力的灌注料。联接器的内部包括帮助将灌注料保持在连接器中的台肩166。如期望的那样，现场设备联接器122还可以包括用于提供可调节性的管套节和/或弯管。在一种实施方式中，通过使导线158、160贯穿馈通组件140中的凝结接头164而设置防爆屏障。该凝结接头164通过用能够承受爆炸压力的灌注料填充馈通组件140而形成。
在另一种实施方式中，馈通组件140可以由热固性环氧树脂空心圆筒162构造而成。导线158，160贯穿圆筒162，随后用灌注料164填充该圆筒162。馈通组件140滑入现场设备联接器122中，现场设备联接器122的台肩166抵靠在馈通组件140的表面168上。严格控制圆筒形馈通组件140的外径和现场设备联接器122的内径以及二者的长度，以维持足够长且窄的间隙170，以熄灭任何试图溢出的燃烧气体。馈通组件140的外径优选还包括用于环境密封的O形环172。
无线过程通信适配器30因此优选地采用馈通组件的密封和适应以提供爆炸和环境保护，并为本质安全保护降低电子元件之间所要求的间距。当元件之间的空间用灌注料填充时，对本质安全间距要求不严格。这允许更有效地最小化整个设备。密封通过完全排除可燃气体而实现防爆。无线过程通信适配器30的电子组件完全由灌注料包围，因此避免受到环境的影响。
塑料和灌注料都具有优点和缺点，它们一些使用，以补偿彼此的缺点。塑料可以用来提供刚性壳体、防紫外性和耐燃性，这些是不能从大多数灌注成分获得的。灌注料从内部支撑塑料，由此改善其抗冲击性。灌注料提供为机构批准所要求的耐化学性，并致使水密和防尘等级没有实际意义，因为实际上水和灰尘不可能到达电子组件。灌注料还使得电子组件实际上不受振动的影响，且更紧密的本质安全间距允许使用更小的电路板。这种设计产生紧凑的封装，仅具有一个防爆节点，引线从那里离开过程通信适配器30。天线126被保持在设备中，排除了对外部天线的需求，保留防爆。
虽然已经参照优选实施方式描述了本发明，但本领域技术人员将会认识到，在不偏离本发明的精神和范围的前提下可以在形式和细节方面进行改变。

Claims (18)

1.一种无线过程通信适配器，包括：
壳体，具有多个开口；
端盖，连接至所述多个开口中的第一开口；
现场设备联接器，设置在所述多个开口中的第二开口处；
其中，壳体、端盖和现场设备联接器在其中限定腔室；
设置在该腔室内的至少一个电路板，所述电路板具有无线通信电路系统并能够通过现场设备联接器连接至有线现场设备；并且
其中，基本上所述腔室内的所有剩余体积都用固体材料填充，
所述现场设备联接器包括在至有线现场设备的连接位置处的防爆屏障。
2.根据权利要求1所述的无线过程通信适配器，其中无线通信电路系统是本质上安全的。
3.根据权利要求1所述的无线过程通信适配器，其中固体材料为环氧树脂。
4.根据权利要求1所述的无线过程通信适配器，其中壳体为圆筒形。
5.根据权利要求1所述的无线过程通信适配器，其中壳体至少部分地由金属构造。
6.根据权利要求5所述的无线过程通信适配器，其中无线过程通信适配器的底盘能够连接至有线现场设备的电接地。
7.根据权利要求1所述的无线过程通信适配器，其中防爆屏障包括压力阻塞馈通装置。
8.根据权利要求7所述的无线过程通信适配器，其中压力阻塞馈通装置包括抵靠在现场设备联接器的台肩上的表面。
9.根据权利要求7所述的无线过程通信适配器，其中压力阻塞馈通装置具有外径，该外径与现场设备联接器的内径协作，以形成大小能够熄灭燃烧气体的间隙。
10.根据权利要求7所述的无线过程通信适配器，还包括围绕现场设备联接器设置的O-形环。
11.根据权利要求1所述的无线过程通信适配器，其中防爆屏障包括导体从中穿过的凝结接头。
12.根据权利要求1所述的无线过程通信适配器，其中至少一个电路板包括大体上彼此平行设置且由用固体材料填充的间隙隔开的多个电路板。
13.一种无线过程通信适配器，包括：
壳体，具有多个开口；
端盖，连接至所述多个开口中的第一开口；
现场设备联接器，设置在所述多个开口中的第二开口处；
其中，壳体、端盖和现场设备联接器在其中限定腔室；
设置在该腔室内的至少一个电路板，所述电路板具有无线通信电路系统并能够通过现场设备联接器连接至有线现场设备；并且
其中现场设备联接器构造为包括在至有线现场设备的连接位置处的防爆屏障。
14.根据权利要求13所述的无线过程通信适配器，其中防爆屏障包括压力阻塞馈通装置。
15.根据权利要求14所述的无线过程通信适配器，其中压力阻塞馈通装置包括抵靠在现场设备联接器的台肩上的表面。
16.根据权利要求14所述的无线过程通信适配器，其中压力阻塞馈通装置具有外径，该外径与现场设备联接器的内径协作，以形成大小能够熄灭燃烧气体的间隙。
17.根据权利要求13所述的无线过程通信适配器，还包括围绕现场设备联接器设置的O-形环。
18.根据权利要求13所述的无线过程通信适配器，其中防爆屏障包括导体从中穿过的凝结接头。
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