CN101517504A - 生产过程控制回路监控装置 - Google Patents
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Abstract
本发明公开一种过程控制回路监控装置,包括设置为安装在生产过程现场中的外壳(50)。回路接口电路(62)连接到过程控制回路(18)并且从过程控制回路(18)接收数据。存储器(64)存储通过回路接口电路(62)从过程控制回路(18)接收的数据。
Description
技术领域
本发明涉及用于监控和/或控制生产过程的操作的类型的过程控制***。更具体地,本发明涉及监控在这种***中使用的过程控制回路中的数据。
背景技术
在生产过程控制工厂中使用现场设备(诸如过程控制装置、监控装置和传送装置的设备)以遥控或者感知过程参数。例如,诸如温度、压力等等过程参数可以通过过程参数传送装置传送到控制室。被感知的过程参数可以被用于控制过程或者提供给操作者关于过程操作的信息。例如,涉及过程流体的压力的信息可以被传送到控制室,并被用于通过诸如控制炼油厂中的阀而控制过程。
可以通过很多技术实现与现场设备通信。一个技术是通过使用过程控制回路。这种过程控制回路具有用于传输数据的两根线。在一些装配中,两根线也被用于为现场设备供电。一个过程控制回路信号协议是用于代表过程参数的4-20mA信号。另一个信号技术是叠加数字信息在4-20mA信号之上的通信协议。另一个技术通常称为Fieldbus通信协议,在此协议中的回路上的模拟电流水平不用于传送信息,并且数字地传送全部数据。
当通信协议的复杂性已经提高时,在生产过程中的现场设备的网络结构的复杂性也已经提高。在装配有复杂网络布局中,诊断和识别涉及通信网络的故障可能特别困难。
发明内容
过程控制回路监控装置包括回路接口电路,回路接口电路设置为连接到过程控制回路并从过程控制回路接收数据。存储器存储通过回路接口电路从过程控制回路接收的数据。在一个结构中,回路监控装置在主机中实现,主机也被用于完成在过程控制回路上的其它设备的设置的功能。
附图说明
图1是包括过程控制回路监控装置的过程控制***的简图;
图2是图1中显示的过程控制回路监控装置的框图;
图3是说明根据本发明的登录数据的步骤的简化的框图;和
图4是显示涉及储存的数据的恢复步骤的简化的框图。
具体实施方式
如在背景技术部分中所述,过程装置网络结构可以是复杂的,因而问题可能难以诊断。例如,Fieldbus装置的装配可能需要复杂的网络布局。这个复杂性可能导致网络问题以及诊断这种问题的困难。这可能导致额外的维修请求以诊断网络相关问题。当生产过程位于遥远的区域中时,或者当服务人员在诊断网络相关问题中是无经验时,这种情况可能是特别地麻烦。本发明提供过程控制回路监控装置,设置为安装在生产过程的现场中并且从二线回路收集数据。数据被储存在存储器中,并且可由技术人员随后使用以识别在过程控制回路网络中的故障。
图1是包括过程控制回路监控装置8的生产过程控制或监控***10的示图。回路监控8在生产过程的现场中安装到支撑6。过程控制***10还包括连接到过程管16的传送装置12和阀***22。传感器21一般地显示在图1中,并且连接到传送装置12。图1也显示阀***22,所述阀***22连接到控制元件24,所述控制元件24可以包括,例如,阀。
用于在生产过程控制和监控***中传送信息的一个典型技术包括控制流过过程控制回路的电流量。电流从在控制室中的电流源供应,并且过程参数传送装置基于感知的过程参数控制电流。例如,4mA电流信号可以被用于指示零点读数,20mA信号可以被用于指示满刻度读数。类似地,在控制室中被控制的电流水平可以被用于控制阀***等等。新近,传送装置应用了使用数字信号与控制室通信的数字电路,,数字信号叠加在流过过程控制回路的模拟电流信号上。这种技术的一个实施例是通信协议。
Fieldbus是通过Fieldbus基金会(Fieldbus Foundation)发展的通信协议,并且被指向以限定用于在过程控制回路上传送信息的通信层或者协议。在Fieldbus协议中,流过回路的电流不被用于传送模拟信号。而是,全部信息是数字地传送。而且,Fieldbus标准和称为Profibus的标准允许传送装置设置在多传输线结构中,其中多于一个的传送装置被连接在相同的过程控制回路上。其它通信协议包括协议和以太网(Ethernet)。在一些结构中,二线、三线、四线或者多线可以被用于连接到包括非物理连接器诸如RF(射频)的过程装置。
过程控制回路监控装置8、传送装置12和***22被连接到根据Fieldbus、Profibus或者标准操作的过程控制回路18。然而,本发明不限于这些标准或者二线结构。过程控制回路18在现场中的位置和控制室20之间延伸。在实施例中,回路18根据协议操作,回路18能够传送代表被感知的过程参数的电流I。另外,协议允许数字信号叠加在经过回路18的电流上,以至于数字信息可以被传送到传送装置12或者从传送装置12接收。当根据Fieldbus标准操作时,回路18传送数字信号,并且可以被连接到诸如其它传送装置的多个现场设备。许多过程控制回路18可适当地被使用并连接到现场安装的设备。这里显示的结构仅为示例的目的。
如上所述,图1是显示过程控制***10的实施例的图,过程控制***10包括运载过程流体的过程管16和传送回路电流I的过程控制回路18。传送装置12、控制器22(其连接到在回路中的最终控制元件,诸如执行机构(actuator)、阀、泵、电动机或者螺线管)、通信装置26和控制室20都是过程控制回路18的一部分。应当理解,在一种配置中显示回路18,并且可以使用任何适当的过程控制回路,诸如4-20mA回路,2、3或4线回路,多传输线回路和根据Fieldbus或其它数字或模拟通信协议操作的回路。而且,这种过程控制回路可以采用多种无线技术。
在操作中,传送装置12使用传感器21感知诸如流量(flow)的过程参数,并且在回路18上传送感知的过程参数。过程参数可以通过控制器/阀执行机构22和/或控制室设备20接收。控制器22显示为连接到阀24,并且能够通过调整阀24控制过程,从而改变管16中的流量。控制器22从例如控制室20或传送装置12接收回路18上的控制输入,并响应地调整阀24。在另一个实施例中,控制器22基于在回路18上接收的过程信号在内部产生控制信号。过程设备包括显示在图1中的例如传送装置12(诸如可从Rosemount公司获得的3051S压力传送装置)、控制器22、过程控制回路监控装置8和控制室20。过程装置的另一个类型是使用适当的I/O电路连接到回路的PC、可编程逻辑单元(PLC)或其它计算机,以允许对回路的监控、管理和/或在回路上的传送。
图2显示过程控制回路监控装置8的简图。回路监控8包括设置以连接到支撑6的外壳50。在显示在图2中的结构中,过程控制回路监控8设计为具有与典型的过程控制传送装置相似的形状因素。然而,任何适当的设计可被使用。另外,用于将过程控制回路监控装置8连接到支撑6的支架52可以根据标准设计设置,以至于可使用具有现存的支架类型以安装过程传送装置。
如图2中所述,过程控制回路监控装置8包括微控制器60、输入/输出电路62和存储器64。在操作过程中,输入/输出电路62连接到过程控制回路18,并且监控在回路18上传送的数据通信。在一些结构中,输入/输出电路62还包括电力输出,其向监控8中的电路供电,所述电力输出产生自回路18上传送的电流I。在一些结构中,输入/输出电路62包括只输入电路并且被设置为只接收来自过程控制回路18的数据输入。微控制器60可以是相对简单的电路,设置为将从回路18接收的一些或全部数据储存在存储器64中。从回路18收集的数据的登录可以基于触发器来进行,例如从回路18接收的、周期性地触发或者在确定的时间处触发的特殊类型数据或者事件。例如,连接到微控制器60的时钟66可以被用于为微控制器提供时间信息。这个时间信息可在一些结构中被使用,以控制在存储器64中登录数据。另外,如果登录的数据是用实时时间时钟表示的时间,所述数据可以随后与在该时间期间的过程控制回路中的其它活动相比,以识别在回路18中的问题。
存储器64可以是任何类型适当的存储器。优选地,存储器64是非易失性存储器,以使监控装置8可以断开电源而没有丢失储存在存储器64中的数据。
图3是框图80,说明本发明的过程监控装置8的操作的实施例。首先,提供可选的触发器块82。可选的触发器块82可以被用于启动数据捕获。例如,数据捕获可以被在确定时间处、周期性地或者基于一些其它事件而启动。在块84处,在过程控制回路18上接收数据。另一个可选触发器块86可以被用以确定是否要登录收集的数据。例如,可以根据诸如特别的过程装置或特别的数据类型检测接收的数据,以确定是否是期望的用于登录的类型。在可选的块86处,如果触发器没有被激活,控制可以被传递回到块84(或者可选块82)。另一方面,如果触发器被激活,控制被传到可选的数据过滤器86。可选的数据过滤器86可以被用于选择地过滤什么类型的数据将被登录。例如,如果期望在存储器64中保持空间,可以从数据中剥去从过程控制回路中接收的诸如可选的报头(header)等等无关的数据。在块90处可以提供可选的时间标记。时间标记可从在图2中显示的时钟66中产生,并且可以是实际时间数据或者可以是一些相对时间的类型。在块92处,数据被储存进存储器64并且控制被传到可选块94。如果可选块94不存在,控制可以被返回到块84(或者可选块82)。在可选块94处,确定是否继续进行数据登录。可以基于诸如时间、登录的数据点的数目、存储器64所剩的空间量等等任何适当的标准来进行该确定。如果继续进行登录,控制被传递回到块84(或者可选块82)。另一方面,如果停止进行数据登录,控制被传到块96。
在一些结构中,可以例如通过在过程控制回路18上发送命令到回路监控装置8来控制数据的登录。在一个实施例中,可以配置图3中所示的流程图的特征。例如,触发器82和86、数据过滤器88以及时间标记90是可配置的。登录的数据量、登录频率(例如,在回路18上接收的每个第n个信息的登录)、是否擦除存储器等等是可以配置的。可配置的参数的另一个实施例为存储器是否是循环的以使旧的登录最终被新的数据重写。
一旦期望的数据量已经被登录进存储器64,或者一些其它的周期以后,由服务人员收集数据用于计算。可以根据任何适当的技术收集数据。可以在过程控制回路18上或者通过显示在图2中的可选数据输入/输出连接器70下载数据。例如,数据输入/输出连接器70可以是满足诸如RS232、USB等等的已知标准的插头。在另一个实施例中,数据输入/输出70可被用于存取和编程微控制器60,例如,以控制如何登录数据和与这种登录相关的参数。在另一个实施例中,诸如通过使用射频(RF)、电感耦合、声音耦合、光耦合等等,数据输入/输出使用无线通信技术。过程监控装置8可选地从现场移除,并返回到维修位置以计算。在另一个实施例中,存储器64被在可移除的模块中运载,以至于其可以被从过程监控装置8中移除。例如,图2中显示的末端盖72可以被从外壳50上移除,以允许接近存储器64。存储器可以包括诸如紧凑闪存(compact flash)、安全数字卡等等标准的可移除的模块。
图4是显示与储存的数据的恢复相关的步骤的框图100。在块102处,储存在存储器64中的数据通过任何适当的技术被检索。接着,在块104处,储存的数据被检查。例如,数据可以与其它数据相比,与已知的好数据等等比较。基于该检查,在块106处,***被诊断,例如,以识别网络错误或过程控制回路中的其它问题。
虽然本发明已经参照优选的实施例进行了说明,在不背离本发明的精神和范围的条件下,本领域技术人员认识到可在形式和细节上进行改变。在一个具体实施例中,回路监控装置不包含诸如传感器或者控制元件的任何过程接口元件。回路监控装置可以在用于在过程控制回路上配置其它设备的类型的主机装置中实现。主机装置可以在PC、手持设备和其它设备中实现。在这种结构中,装置8包括主机装置,且I/O电路62(参见图2)用于发送配置命令到回路18上的设备。
权利要求书(按照条约第19条的修改)
1.一种过程控制回路监控装置,包括:
外壳,所述外壳设置为安装在生产过程控制或者监控***的现场;
过程控制回路接口电路,设置为连接到过程控制回路并且从所述过程控制回路接收数据;和
存储器,设置为登录通过所述接口电路从所述过程控制回路接收的数据,用于服务人员随后的检索。
2.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路接口电路设置为连接到二线过程控制回路。
3.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路监控装置由从过程控制回路接收的电力供电。
4.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路根据Fieldbus通信标准传送数据。
5.根据权利要求1所述的过程控制回路监控装置,其中:所述存储器是可移除的。
6.根据权利要求1所述的过程控制回路监控装置,包括:时钟。
7.根据权利要求6所述的过程控制回路监控装置,其中:储存在存储器中的数据是标记有来自所述时钟的时间信息的时间。
8.根据权利要求6所述的过程控制回路监控装置,其中:所述时钟包括实时时钟。
9.根据权利要求1所述的过程控制回路监控装置,其中:所述外壳设置为装配到在过程控制或者监控***中的标准化的连接装置。
10.根据权利要求1所述的过程控制回路监控装置,包括:微控制器,所述微控制器设置为将数据登录在所述存储器中。
11.根据权利要求10所述的过程控制回路监控装置,其中:所述微控制器包括触发器,所述触发器设置为触发所述数据的登录。
12.根据权利要求10所述的过程控制回路监控装置,其中:所述微控制器设置为过滤从过程控制回路中接收的数据。
13.根据权利要求1所述的过程控制回路监控装置,其中:储存在存储器中的旧的数据用新的数据改写。
14.根据权利要求1所述的过程控制回路监控装置,包括:连接器,所述连接器设置为从所述存储器中检索数据。
15.根据权利要求1所述的过程控制回路监控装置,包括:连接器,所述连接器设置为控制数据登录参数。
16.一种诊断用在过程控制或者监控***中的过程控制回路的操作的方法,包括:
(a)从过程控制回路中接收现场安装的回路监控装置中的数据;
(b)将所接收的数据登录在存储器中;
(c)重复步骤(a)和(b);和
(d)由服务人员检索所登录的数据。
17.根据权利要求16所述的方法,包括基于所检索的登录数据诊断过程控制回路。
18.根据权利要求16所述的方法,其中:所述过程控制回路包括二线过程控制回路。
19.根据权利要求16所述的方法,其中:所述过程控制回路根据Fieldbus通信标准传送数据。
20.根据权利要求16所述的方法,包括:从所述回路监控装置移除所述存储器。
21.根据权利要求16所述的方法,包括:对所登录的数据标记时间。
22.根据权利要求16所述的方法,包括:将所述回路监控装置安装到过程控制和监控***中的标准连接。
23.根据权利要求16所述的方法,包括:登录响应触发的数据。
24.根据权利要求16所述的方法,包括:过滤从过程控制回路接收的数据。
25.根据权利要求16所述的方法,包括:传送输入/输出连接器,该连接器设置为从所述存储器检索数据。
26.一种过程控制回路监控装置,包括:
过程控制回路接口电路,所述过程控制回路接口电路设置为连接到过程控制回路并且从所述过程控制回路接收数据;
存储器,所述存储器设置为登录通过接口电路从过程控制回路接收的数据,用于服务人员随后的使用;和
其中所述过程控制回路接口电路还设置为发送配置命令到连接到所述过程控制回路的现场设备。
Claims (26)
1.一种过程控制回路监控装置,包括:
外壳,所述外壳设置为安装在生产过程控制或者监控***的现场;
过程控制回路接口电路,设置为连接到过程控制回路并且从所述过程控制回路接收数据;和
存储器,设置为登录通过所述接口电路从所述过程控制回路接收的数据。
2.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路接口电路设置为连接到二线过程控制回路。
3.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路监控装置由从过程控制回路接收的电力供电。
4.根据权利要求1所述的过程控制回路监控装置,其中:所述过程控制回路根据Fieldbus通信标准传送数据。
5.根据权利要求1所述的过程控制回路监控装置,其中:所述存储器是可移除的。
6.根据权利要求1所述的过程控制回路监控装置,包括:时钟。
7.根据权利要求6所述的过程控制回路监控装置,其中:储存在存储器中的数据是标记有来自所述时钟的时间信息的时间。
8.根据权利要求6所述的过程控制回路监控装置,其中:所述时钟包括实时时钟。
9.根据权利要求1所述的过程控制回路监控装置,其中:所述外壳设置为装配到在过程控制或者监控***中的标准化连接装置。
10.根据权利要求1所述的过程控制回路监控装置,包括:微控制器,所述微控制器设置为将数据登录在所述存储器中。
11.根据权利要求10所述的过程控制回路监控装置,其中:所述微控制器包括触发器,所述触发器设置为触发所述数据的登录。
12.根据权利要求10所述的过程控制回路监控装置,其中:所述微控制器设置为过滤从过程控制回路中接收的数据。
13.根据权利要求1所述的过程控制回路监控装置,其中:储存在存储器中的旧的数据用新的数据改写。
14.根据权利要求1所述的过程控制回路监控装置,包括:连接器,所述连接器设置为从所述存储器中检索数据。
15.根据权利要求1所述的过程控制回路监控装置,包括:连接器,所述连接器设置为控制数据登录参数。
16.一种诊断用在过程控制或者监控***中的过程控制回路的操作的方法,包括:
(a)从过程控制回路中接收现场安装的回路监控装置中的数据;
(b)将所接收的数据登录在存储器中;
(c)重复步骤(a)和(b);和
(d)检索所登录的数据。
17.根据权利要求16所述的方法,包括基于所检索的登录数据诊断过程控制回路。
18.根据权利要求16所述的方法,其中:所述过程控制回路包括二线过程控制回路。
19.根据权利要求16所述的方法,其中:所述过程控制回路根据Fieldbus通信标准传送数据。
20.根据权利要求16所述的方法,包括:从所述回路监控装置上移除所述存储器。
21.根据权利要求16所述的方法,包括:对所登录数据标记时间。
22.根据权利要求16所述的方法,包括:将所述回路监控装置安装到过程控制和监控***中的标准化连接装置。
23.根据权利要求16所述的方法,包括:响应于触发器登陆数据。
24.根据权利要求16所述的方法,包括:过滤从过程控制回路接收的数据。
25.根据权利要求16所述的方法,包括:传送输入/输出连接器,该连接器设置为从所述存储器检索数据。
26.一种过程控制回路监控装置,包括:
过程控制回路接口电路,所述过程控制回路接口电路设置为连接到过程控制回路并且从所述过程控制回路接收数据;
存储器,所述存储器设置为登录通过接口电路从过程控制回路接收的数据;和
其中所述过程控制回路接口电路还设置为发送配置命令到连接到所述过程控制回路的现场设备。
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PCT/US2007/020182 WO2008039326A2 (en) | 2006-09-25 | 2007-09-18 | Industrial process control loop monitor |
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CN104216355A (zh) * | 2013-06-03 | 2014-12-17 | 泰思康公司 | 用于现场设备的控制和监控的***和方法 |
CN104428726A (zh) * | 2013-07-13 | 2015-03-18 | 费斯托股份有限两合公司 | 数据采集单元以及自动化*** |
CN104428726B (zh) * | 2013-07-13 | 2017-03-01 | 费斯托股份有限两合公司 | 数据采集单元以及自动化*** |
CN105938361B (zh) * | 2015-03-04 | 2018-09-21 | 西门子公司 | 用于监控调节回路的运行的诊断装置和诊断方法 |
US10175685B2 (en) | 2015-03-04 | 2019-01-08 | Siemens Aktiengesellschaft | Diagnostic device and method for monitoring the operation of control loops |
CN106371419A (zh) * | 2015-07-22 | 2017-02-01 | 西门子公司 | 用于监视控制回路的运行的诊断装置和诊断方法 |
CN106371419B (zh) * | 2015-07-22 | 2018-10-16 | 西门子公司 | 用于监视控制回路的运行的诊断装置和诊断方法 |
US10394255B2 (en) | 2015-07-22 | 2019-08-27 | Siemens Aktiengesellschaft | Diagnostic device and method for monitoring frictional behavior in a control loop |
Also Published As
Publication number | Publication date |
---|---|
JP5130532B2 (ja) | 2013-01-30 |
RU2419828C2 (ru) | 2011-05-27 |
EP2067083A2 (en) | 2009-06-10 |
RU2009115650A (ru) | 2010-11-10 |
US20080126861A1 (en) | 2008-05-29 |
US7953501B2 (en) | 2011-05-31 |
WO2008039326A2 (en) | 2008-04-03 |
WO2008039326B1 (en) | 2008-09-04 |
WO2008039326A3 (en) | 2008-07-10 |
CN101517504B (zh) | 2011-09-28 |
JP2010504597A (ja) | 2010-02-12 |
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