CN105469584A - 用于过程设备无线适配器的改善的形状因素和电磁干扰保护 - Google Patents
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Abstract
一种过程设备无线适配器，包括无线通信模块、金属壳体和天线。无线通信模块构造为可通信地连接至过程设备并连接至无线接收器。金属壳体围绕无线通信模块，并具有第一端和第二端。所述第一端构造为连接至过程设备。在一种实施方式中，金属护罩接触金属壳体的第二端，以便金属护罩和金属壳体形成大致连续的导电面。天线可通信地连接至无线通信模块，并由金属护罩与无线通信模块隔开。
Description
本申请是申请号为200980122613.X的中国发明专利申请(申请日：2009年6月17日；发明名称：用于过程设备无线适配器的改善的形状因素和电磁干扰保护)的分案申请。
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。现场设备通常在分布式控制或过程监控系统中执行一定功能，如感测参数或根据过程进行运转。
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、定位器、传动装置、螺线管、指示灯以及其它。
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进行动作。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。
发明内容
一种过程设备无线适配器，包括无线通信模块、金属壳体和天线。无线通信模块构造为可通信地连接至过程设备并连接至无线接收器。金属壳体围绕无线通信模块，并具有第一端和第二端。所述第一端构造为连接至过程设备。在一种实施方式中，金属护罩接触壳体的第二端，以便金属护罩和壳体形成大致连续的导电面。天线可通信地连接至无线通信模块，并由金属护罩与无线通信模块隔开。优选地，无线通信模块示例性地包括印刷电路板，其具有大于其宽度的长度。
附图说明
图1为根据本发明的无线适配器与其一起使用的示例性现场设备的示意图。
图2为图1中示出的现场设备的框图。
图3为连接至过程设备的形状因素改善的无线适配器的透视图。
图4为图3的无线适配器的剖面透视图。
图5为包括无线适配器的过程控制或监控系统的简化框图。
图6为根据本发明的实施方式的减少或消除电磁干扰的无线适配器的剖视图。
图7为根据本发明的实施方式的减少或消除电磁干扰的另一无线适配器的剖视图。
图8为示出连接至过程设备的无线适配器的简化剖视图。
具体实施方式
本发明的实施方式主要包括无线适配器，其构造为连接至过程设备并与过程控制室或在计算机上运行的远程监控系统或诊断应用程序进行通信。过程设备通常安装在具有受限访问的区域中。在此描述的一些实施方式包括形状因素改善的无线适配器。改善的形状因素使得无线适配器能够连接至多种环境中的过程设备，包括否则不允许无线适配器连接至过程设备的环境。过程设备通常还安装在具有可能负面影响无线适配器的性能和运转产生的电磁干扰(EMI)的环境中。在此描述的一些实施方式包括具有减少或消除EMI的负面效应的导电外壳的无线适配器。
图1和2为根据本发明的实施方式的无线适配器一起使用的示例性现场设备的示意图和框图。过程控制或监控系统10包括通过二线式过程控制回路16连接至一个或多个现场设备14的控制室或控制系统12。过程控制回路16的例子包括模拟4-20mA通信，包括模拟和数字通信的诸如高速可编程远程换能器标准的混合协议，以及诸如FOUNDATIONTMFieldbus标准之类的全数字协议。通常，过程控制回路协议既可以向现场设备供电，又允许在现场设备和其它设备之间进行通信。
在这个例子中，现场设备14包括电路18，其经由壳体23中的接线板21连接至致动器/换能器20，并连接至过程控制回路16。现场设备14图示为过程变量产生装置，其中它连接至过程，并感测一个方面，如过程的温度、压力、pH、流量或其它物理性能，并提供对它们的表示。现场设备的其它例子包括阀、致动器、控制器和显示装置。
通常，现场设备的特征在于它们的在“现场”运行的能力，所述现场可能将它们暴露至环境应力，如温度、湿度和压力。除了环境应力，现场设备必须承受至腐蚀性、危险性和/或甚至爆炸性气氛的暴露。而且，这种设备还必须在存在振动和/或电磁干扰的情况下运行。图1中图示的种类的现场设备表示相对大的传统设备的安装基座，其设计为以完全有线的方式运行。
图3为连接至过程设备350的形状因素改善的无线适配器300的透视图，图4为适配器300的剖面透视图。适配器300包括经由标准现场设备导管352连接至设备350的机械连接区域301(如，具有螺纹面的区域)。适合的导管连接的例子包括1/2-14NPT、M20x1.5、G1/2和3/8-18NPT。作为示例，通过围绕旋转轴370旋转适配器300，适配器300连接至或从设备上脱离。连接区域301优选是中空的，以允许导体344将适配器300连接至设备350。
适配器300包括外壳主体或壳体302和端盖304。壳体302和盖304为包括在适配器300内的元件提供环境保护。如图4中可以看到的那样，壳体302封闭或围绕一个或多个无线通信电路板310。作为示例，每个电路板310具有矩形形状，并具有沿着或平行于旋转轴370(图3中示出)延伸的长度312。每个板310还具有从旋转轴370径向向外或垂直于旋转轴370的宽度314。
在一种实施方式中，调整或选择电路板长度312和宽度314，使得适配器300能够连接至处于各种环境中的过程设备350。例如，过程设备350可能位于对电路板310的宽度314仅具有有限量的空间的环境中。在这种情况中，电路板的宽度314减小，使得它可以装配到这种环境中。电路板的长度312相应地增加，以补偿减小的宽度314。这使得电路板310能够包括所有需要的元件，同时具有适合过程设备环境的形状因素。在一种实施方式中，长度312大于宽度314(即，长度与宽度之比大于1)。然而，本发明的实施方式不限于任何特定的比值或尺寸。还应当注意到，作为示例，调整壳体302和盖304的长度和/或直径，以便最小化无线适配器300的总长度和直径/宽度(即，体302和盖304的长度和直径大小形成为仅与需要的一样大，以容纳所封闭的元件)。
图5为过程控制或监控系统500的简化框图，其中控制室或控制系统502通过无线适配器300通信地连接至现场设备350。无线适配器300包括无线通信模块310和天线320。无线通信模块310连接至过程设备控制器356，并基于来自控制器356的数据经由天线320与外部无线设备(如，如图5中所示的控制系统502或其它无线设备或监控系统)交互作用。取决于应用，无线通信模块310可以适于根据任何适合的无线通信协议进行通信，包括但不限于：无线网络技术(如California州由Irvine市的Linksys搭建的IEEE802.11b无线接入点和无线网络设备)；蜂窝或数字网络技术(如California州SanJose市的AerisCommunications公司的)；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BluetoothSIG(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规范。无线规范的相关部分包括：HCF_Spec13，7.0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。而且，可以采用已知的数据冲突技术以使在彼此的无线操作范围内多单元可以共存。这个冲突防止可以包括使用多个不同无线电频率通道和/或扩展频谱技术。
无线通信模块310还可以包括用于多种无线通信方法的换能器。例如，主无线通信可以采用相对长距离的通信方法，如采用GSM或GPRS进行，而对靠近单元的技术人员或操作人员可以提供次级或其它通信方法，例如采用IEEE802.11b或蓝牙。
现场设备350还包括电源电路352和致动器/换能器354。在一种实施方式中，来自模块352的能量激励控制器356，以与致动器/换能器354和无线通信模块310交互作用。来自模块352的能量还可以激励无线适配器300的元件。过程设备控制器356和无线通信模块310示例性地根据诸如4-20mA、FOUNDATIONTMFieldbus、Profibus-PA、Modbus或CAN之类的标准工业协议彼此交互作用。可替换地，无线适配器可以由其自身的电源(如电池)供电，或者由其它源供电，如由能量收集(energyscavenging)供电。
图6为根据本发明的实施方式的减少或消除电磁干扰(EMI)的无线适配器600的剖视图。适配器600包括无线通信模块电子组件602(如，一个或多个印刷电路板)、天线604、金属壳体或外壳606、金属护罩608、非金属端盖610(如，塑料天线罩)、以及导电弹性垫圈612。作为示例，金属外壳606由金属化塑料或由诸如铝之类的金属制成，并具有圆筒形形状。作为示例，金属护罩608由具有导电材料的塑料板或由诸如冲压金属片之类的金属制成。
垫圈612装配到外壳606的圈环613内。垫圈612与金属外壳606和金属护罩608都接触，以便这三个元件形成连续的导电面。这种导电面保护无线通信模块602免受EMI的影响。
金属护罩608具有小洞或孔609。孔609允许电连接630(如同轴电缆)穿过壳体608，并将天线604连接至无线通信模块602。可替换地，天线604可以与模块602一体地形成，例如以在电路板的外边缘附近布线的迹线形式。在这种情况中，一体形成的天线604通过孔609穿过壳体608。
非金属端盖610和金属护罩608围绕天线604，并为天线提供物理保护(如，环境保护)。无线信号能够穿过非金属端盖610。这允许天线604传输和接收无线信号。在一种实施方式中，壳体608和天线604设计为使得壳体608为天线604的接地面板的一部分。
金属外壳606具有小洞或孔607。孔607允许电导体或连接611穿过。作为示例，连接611将无线适配器600连接至过程设备，以便可以在无线适配器600和过程设备之间传递通信信号。作为示例，适配器600根据诸如上文提到的那些工业协议(如，)与过程设备通信。连接611还可以向无线适配器600供电(如，电流或电压)。
图7为根据本发明的实施方式的减少或消除EMI的另一无线适配器700的剖视图。适配器700包括大量与适配器600相同或相似的元件，因此采用相同的标记。适配器700不包括类似于适配器600的导电垫圈。相反，金属护罩708具有导电突出体或弹簧夹718。弹簧夹718装配在外壳圈环712内，以便壳体708和外壳706形成围绕无线通信模块702的连续导电面。围绕的导电面包含模块702内的电子组件免受EMI的影响。
在无线适配器的另一种实施方式中，电子组件外壳(如，图6中的壳体606和图7中的外壳706)由非金属材料制成。无线适配器通信电子组件(如，图6中的模块602和图7中的模块702)示例性地由位于电子组件外壳内并围绕电子组件的单独的金属护罩保护免受EMI的影响。
在无线适配器的又一种实施方式中，适配器不包括包围天线的端盖(如，图6中的端盖610)。相反，使用“橡胶帆布”类型的鞭状天线。鞭状天线靠近适配器壳体(如，图6中的壳体608)定位或放置，并暴露至环境。
无线适配器示例性地形成为满足本质安全要求，并提供防燃烧(防爆)能力。此外，无线适配器可选地包括位于它们的电子组件外壳内的灌注料，以进一步包括封闭的电子组件。在这种情况中，无线适配器的金属护罩可以包括一个或多个槽口和/或孔，以便于灌注流。
图8为根据本发明一种实施方式的连接至过程设备850的无线适配器800的剖视图。设备850包括致动器/换能器864和测量电路866。测量电路866连接至现场设备电路868。设备850通过端子板806和无线适配器800连接至二线式过程控制回路888。而且，无线适配器800连接至设备850的壳体。在图8中示出的例子中，联接器穿过NPT导管连接809。无线适配器800的底盘示例性地通过导线808连接至设备850的电接地连接810。设备850包括二线式过程控制回路端子板802，其连接至来自无线适配器800的连接812。如图8所示，无线适配器800可以被以螺纹方式容纳在导管连接809中。壳体820带有天线826，以支撑无线适配器800的电路。而且，端盖824可以密封地连接至壳体820，并允许从中传输无线信号。注意到在图8中示出的结构中，为无线适配器800设置了五个电连接(即，四个回路连接和一个电接地连接)。然而，这些电的和机械连接方式仅仅是用于说明目的。本发明的实施方式不限于任何特定的电的或机械连接方式，并且实施方式示例性地包括任何电的或机械连接方式。
如在此使用的术语“现场设备”可以为用在过程控制或监控系统中且不必要求放置在“现场”中的任何设备。现场设备包括但不限于，过程变量变送器、数字阀控制器、流量计和流量计算器。该设备可以设置在过程控制系统中的任何位置中，包括在控制室或控制电路中。用来连接至过程控制回路的端子称为电连接，并且可以不包括物理或分离的接线端。可以如任何适合的通信协议、频率或通信技术可以期望的那样使用任何合适的无线通信电路系统。电源元件如期望的那样构造且不限于在此提出的结构或任何其它特定的结构。在一些实施方式中，现场设备包括地址，该地址可以包括在任何传输中，以便可以识别该设备。类似地，这种地址可以用来确定接收到的信号是否用于该特定的设备。然而，在其它实施方式中，不利用地址，从无线通信电路系统简单地传输没有寻址信息的数据。在这种配置中，如果期望接收数据，任何接收到的数据可以不包括寻址信息。在一些实施方式中，这是可以接受的。在其它实施方式中，可以使用其它寻址技术或识别技术，如为特定的设备指定特定的频率或通信协议，向特定的设备指定特定的时隙或时间周期，或其它技术。可以采用任何适合的通信协议和/或网络技术，包括基于标记的技术，在这种技术中，在设备之间交换标记，由此允许特定设备的传输或接收。
如已经讨论的那样，本发明的实施方式改善了与过程设备的无线通信。一些实施方式通过提供围绕并保护封闭的电通信模块或元件的导电面而减少了对无线适配器的电磁干扰。无线适配器的天线示例性地放置在导电面的外面，以便它们可以与控制系统无线通信。可选地，通过将天线用允许无线信号穿过的非金属端盖包围，对天线进行环境保护。此外，实施方式包括改善的形状因素，其使得无线适配器能够连接至处于受限的环境中的过程设备，这种受限的环境可能不允许连接无线适配器。作为示例，通过减小无线适配器的宽度并通过增加该适配器的长度来补偿宽度的减小，改善了形状因素。
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 (21)
1.一种过程设备无线适配器，包括：
无线通信模块，构造为可通信地连接至过程设备并连接至无线接收器；
围绕无线通信模块的金属壳体，该金属壳体具有第一端和第二端，所述第一端构造为直接连接至过程设备；
金属护罩，接触金属壳体的第二端，以便金属护罩和金属壳体形成大致连续的导电面；和
天线，可通信地连接至无线通信模块并由金属护罩与无线通信模块分开。
2.根据权利要求1所述的过程设备无线适配器，其中无线通信模块包括印刷电路板，印刷电路板具有长度和宽度，长度在金属壳体的第一端和金属壳体的第二端之间延伸，并且其中所述长度大于所述宽度。
3.根据权利要求2所述的过程设备无线适配器，其中无线通信模块包括第二印刷电路板，第二印刷电路板具有长度和宽度，第二印刷电路板的长度在金属壳体的第一端和金属壳体的第二端之间延伸，并且其中第二印刷电路板的长度大于第二印刷电路板的宽度。
4.根据权利要求1所述的过程设备无线适配器，还包括：
非金属端盖，连接至金属壳体并包围天线。
5.根据权利要求4所述的过程设备无线适配器，其中非金属端盖为塑料天线罩。
6.根据权利要求1所述的过程设备无线适配器，其中金属壳体包括铝。
7.根据权利要求1所述的过程设备无线适配器，其中金属壳体包括金属化塑料。
8.根据权利要求1所述的过程设备无线适配器，其中金属护罩包括冲压金属。
9.根据权利要求1所述的过程设备无线适配器，其中金属护罩包括镀有导电材料的塑料。
10.根据权利要求1所述的过程设备无线适配器，其中金属护罩通过弹簧夹接触金属壳体的第二端。
11.根据权利要求1所述的过程设备无线适配器，其中金属护罩通过导电弹性垫圈接触金属壳体的第二端。
12.一种过程设备无线适配器，包括：
金属壳体，具有长度、半径、第一端和第二端，该第一端被构造为直接连接至过程设备；
位于金属壳体内的无线通信模块，该无线通信模块包括印刷电路板，该印刷电路板具有宽度和长度，该印刷电路板的长度沿着金属壳体的长度延伸，该印刷电路板的长度大于该印刷电路板的宽度，该印刷电路板构造为可通信地连接至过程设备；
金属护罩，与金属壳体形成连续的导电面，该金属护罩具有第一侧和第二侧，印刷电路板靠近第一侧定位；和
天线，通过金属护罩中的孔电连接至印刷电路板，该天线靠近金属护罩的第二侧定位，该天线构造为向无线接收器无线传输通信并无线接收来自无线接收器的通信。
13.根据权利要求12所述的过程设备无线适配器，其中天线为“橡胶帆布”型鞭状天线。
14.根据权利要求12所述的过程设备无线适配器，其中金属护罩为该天线的接地面的一部分。
15.根据权利要求12所述的过程设备无线适配器，其中在金属壳体内包含灌注料。
16.根据权利要求12所述的过程设备无线适配器，还包括构造为连接至过程设备导管的机械连接区域。
17.根据权利要求16所述的过程设备无线适配器，其中机械连接区域包括螺纹面。
18.一种改善过程设备的无线通信能力的方法，包括下述步骤：
将无线通信模块连接至过程设备；
将天线连接至无线通信模块；
采用由金属壳体和金属护罩形成的连续的导电面至少部分地围绕无线通信模块，以减少对该无线通信模块的电磁干扰，金属壳体具有第一端和第二端，该第一端被构造为直接连接至过程设备，金属护罩接触金属壳体的第二端以形成所述连续的导电面；以及
将天线定位在所述连续的导电面之外，以便能够在过程设备和控制系统之间进行无线通信。
19.根据权利要求18所述的方法，还包括：
将天线包封在非金属盖中，该非金属盖保护天线免受环境的影响并允许无线信号穿过该非金属盖到达控制系统。
20.根据权利要求18所述的方法，还包括：
减小无线通信模块的宽度并增加无线通信模块的长度，使得所述长度大于所述宽度。
21.一种过程设备无线适配器，包括：
无线通信模块，构造为可通信地连接至过程设备和无线接收器；
围绕无线通信模块的金属壳体，该金属壳体具有第一端和第二端，所述第一端构造为直接连接至过程设备；
位于金属壳体内的印刷电路板，该印刷电路板具有宽度和长度，该印刷电路板的长度沿着金属壳体的长度延伸，该印刷电路板的长度大于该印刷电路板的宽度，该印刷电路板构造为可通信地连接至过程设备；和
天线，可通信地连接至无线通信模块并与无线通信模块分开。
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- 2009-06-17 WO PCT/US2009/003611 patent/WO2009154744A1/en active Application Filing
- 2009-06-17 CN CN201510996431.2A patent/CN105469584B/zh active Active
- 2009-06-17 JP JP2011514603A patent/JP5172013B2/ja active Active
- 2009-06-17 CA CA2726613A patent/CA2726613C/en not_active Expired - Fee Related
- 2009-06-17 CN CN200980122613XA patent/CN102067051A/zh active Pending
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Also Published As
| Publication number | Publication date |
|---|---|
| US20090311976A1 (en) | 2009-12-17 |
| CN105469584B (zh) | 2020-06-23 |
| CN102067051A (zh) | 2011-05-18 |
| EP2291716A1 (en) | 2011-03-09 |
| EP2291716B1 (en) | 2018-08-08 |
| US8694060B2 (en) | 2014-04-08 |
| RU2467373C2 (ru) | 2012-11-20 |
| WO2009154744A1 (en) | 2009-12-23 |
| JP5172013B2 (ja) | 2013-03-27 |
| CA2726613A1 (en) | 2009-12-23 |
| RU2011101364A (ru) | 2012-07-27 |
| CA2726613C (en) | 2015-04-14 |
| JP2011525330A (ja) | 2011-09-15 |
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