WO2002017027A2

WO2002017027A2 - Methods and systems for remotely maintaining regulated processes

Info

Publication number: WO2002017027A2
Application number: PCT/US2001/025041
Authority: WO
Inventors: Francis J. Crowe; Virgus L. Volertas; Robert D. Jurenko
Original assignee: Honeywell International Inc.
Priority date: 2000-08-18
Filing date: 2001-08-09
Publication date: 2002-02-28
Also published as: CN1505775A; CA2419959A1; EP1309900A2; JP2004507810A; WO2002017027A3

Abstract

Methods and systems for remote maintenance of regulated devices by a user are disclosed. An embodiment of a system includes a transducer that is integrated to a regulated device and measures data from the regulated device. A microprocessor is operatively coupled to a transducer and processes data received from the transducer. The system can also include a server, which is connected to the microprocessor and processes data received from the microprocessor. The server can be linked to a network that can transmit data between the server and a remote user-controlled device that similarly can be linked to the network. In operation, a user can monitor the performance of regulated devices via the server and can selectively intervene for control of the regulated device(s). Specifically, a user can analyze the operating status of a process using a remote user-controlled device and, using the same device, can alter parameters of the process if necessary by sending a command to the server. The server can subsequently execute the command via a microprocessor controlling the process in order to maintain the performance of the regulated device(s).

Description

METHODS AND SYSTEMS FOR REMOTELY MAINTAINING REGULATED

PROCESSES

TECHNICAL FIELD

The present invention relates generally to the field of diagnostics and process regulation. More specifically, the invention relates to methods and systems for remotely maintaining regulating processes through the use of regulated devices.

BACKGROUND OF THE INVENTION

During the microprocessor-based control of a process, the action of the microprocessor has been primarily limited to the control of the process itself, using the power of the microprocessor to calculate input signal values, internal algorithms and output calculations related to the automatic control algorithm. Vital information about a process and/or regulating device(s) in control of an aspect of a regulated process, however, are not generally known to be accessible by a user. Vital process information related to a regulated process, however, includes useful data regarding the condition or state of a controlled process.

To ensure that a user accurately knows the past and present operating status of a microprocessor-based regulating device(s) generally affecting a regulated process, a user should be able to quickly and easily access both real-time and stored data from a local or remote location. The operating status would generally include the condition or state of the direct and indirect variables used in the control process, such as the condition of the input signals or the number of relay actuations in a process. The status might also include the state of internally derived process-

related calculations, such as timing the duration of the sooting condition for the control of the percentage of carbon in a furnace. A user, therefore, needs to be able to monitor the direct signals, internal calculations, control states and other useful user-configurable data pertaining to the process being controlled. While certain diagnostics systems are currently in commercial use, they are generally limited to locally (e.g., via apparatus/hardware directly connected to a regulating device) monitoring a particular aspect of a regulated process. They are also generally unknown to provide both real-time and stored data from regulating devices. These systems, therefore, tend to provide a user with limited information about a process and the regulated devices in control of a process. While a user can sometimes diagnose the operating status of the regulating device with this limited information, current systems are not typically known to permit a user to directly intervene in a process or schedule maintenance via the regulating device(s) before the wearing-out of a component or the exceeding of a necessary process tolerance. Current diagnostic systems are also generally unknown to permit a user to program dedicated controllers (e.g., microprocessors directly coupled to transducers of regulating devices) to regularly perform a necessary task that presently a user performs manually each time required.

What is apparently needed are systems and methods that go beyond simple local monitoring of microprocessor-regulated processes by providing extensive information about multiple processes and allowing a user to program microprocessors, schedule maintenance, and intervene in a process. Anticipatory intervention via the system would aid process managers in avoiding an emergency repair that could result in costly downtime due to product loss. Remote access to systems (e.g., regulated devices) in control of regulated processes would also provide regulatory agencies with convenient access to inspection-related diagnostic information about the operations of a regulated process for verification purposes. Currently, such agencies are not known to have real-time and/or remote access to requested information and typically must request a recorded printout or other time-delayed rendering.

BRIEF SUMMARY OF THE INVENTION

The following summary of the invention is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

In one aspect of the present invention, a programmable system for maintenance of at least one regulating device via a network by a user is provided. The system can include a server that is linked to a network and is programmed to monitor operations of regulated devices and, ultimately, regulated processes. The server can be programmable to selectively alter parameters of regulating devices. A microprocessor, also connectable to a server, can function as an interface between a server and a regulating device.

In another aspect of the present invention, the system can include a transducer that is operatively coupled to a microprocessor and integrated to a regulating device. The transducer can convert data from a regulating device to a microprocessor, which the microprocessor, in turn, can send to a server. Moreover, the system can include a remote user-controlled device that is linked to a network. In another aspect of the present invention, a user can monitor the operation of a regulating device and can program a server to alter parameters of a regulating device via a network. A server can be connected to a database to permit storage of data from a regulating device. In addition to accessing stored data, a user can monitor real-time data from a regulating device transmitted from a networked server.

Another aspect of the present invention provides methods for a user to monitor and/or maintain operations of regulating devices via a network. A user can begin by logging on to a network with a remote user-controlled device and gaining access to a server via a network. A user can then review data transmitted to a server from a regulating device and can send instruction to a server via a network. A server can subsequently follow the transmitted instruction to selectively alter parameters of at least one regulating device via a microprocessor. Additionally, a server can be connected to a local user- controlled device, permitting a user to maintain a regulating device from an on- site location. A server can also be programmed to follow protocols to notify a user if parameters of a regulating device have been or should be altered, or preventative maintenance is required.

The novel features of the present invention will become apparent to those of skill in the art upon examination of the following detailed description of the invention or can be learned by practice of the present invention. It should be understood, however, that the detailed description of the invention and the specific examples presented, while indicating certain embodiments of the present invention, are provided for illustration purposes only because various changes and modifications within the scope of the invention will become apparent to those of skill in the art from the detailed description of the invention and claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are

incorporated in and form part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.

FIG. 1 illustrates a schematic diagram of a maintenance system for a regulating device; FIG. 2 illustrates a flow diagram relating to an example of general steps taken by a server and a user in maintaining a regulating device;

FIG. 3 illustrates a flow diagram relating to example steps taken by a maintenance system in managing a regulating device; and

FIG. 4 illustrates a flow diagram relating to example steps taken by a user in maintaining a regulating device.

DETAILED DESCRIPTION OF THE INVENTION

The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate an embodiment of the present invention and are not intended to limit the scope of the invention.

In the following example of an embodiment of the present invention, FIG. 1 illustrates a maintenance system 100 for managing the operation of a regulated process device 2. A transducer 4 is integrated to regulated process 2 at a transducer junction 6. Transducer 4 can be designed to measure various types of data, such as heat, light, chemicals, motion, sound, vibration, various electrical signals, etc. A microprocessor 8 is operatively coupled to transducer 4 over a raw data line 10 and in turn is connected to a server 12 over a processed data line 14, which does not have to be a physical connection. A transducer 7 is also integrated with regulated process 2 and is operatively coupled to a microprocessor 11. Microprocessor 11 is shown in close proximity to transducer 7 and is also connected to server 12. An additional transducer 9 is integrated with regulated process 2 and is operatively coupled to a microprocessor 13. Microprocessor 13 is also connected to server 12 and is shown in close proximity to server 12. A database link 18 connects server 12 to a database 16. A network operating system link 30 connects server 12 to a network operating system 28, while a network communications link 26 connects server 12 to a network 24. Network 24 can be public (e.g., Internet, PSTN, etc.) or private (e.g., local area network), as well as wired or wireless (e.g., infrared [IR] or radio frequency [RF] based). Network communications link 26 can comprise an Internet link, an RS 485 communications link using ASCII or MODBUS communications protocols, or any other type of link. A remote communications link 22 can connect a remote user-controlled device 20 with network 24. Remote communications link 22 can be wired or wireless. Remote user-controlled device 20 can be any of various devices, such as a computer terminal, personal digital assistant, or mobile phone. Server 12 is also connectable to a local user- controlled device 32 over a local communications link 34, thereby providing for remote control within a local facility. Local user-controlled device 32 can be any one of various devices, such as a computer terminal, mobile telephone, Internet- enabled telephone (e.g., WAP telephones, web-phone), automobile terminal, or

personal digital assistant.

Regulated devices generally are comprised of the combination of microprocessors and transducers as described in FIG. 1. Referring to FIG. 2, a more detailed illustration of an environment for modules that can comprise a

regulating device 200 is shown. A microprocessor 8 is shown connected to at least one transducer 4. The figure also illustrates that numerous transducers can report into a single microprocessor. The transducers can be connected in common as shown, or can have separate connections to the microprocessor in order to provide separate and/or distinct data to the microprocessor. Microprocessor 8 illustrates the type of data it can control (e.g., transducer regulation, algorithm calculations, process control, alarms, timing, and trending). The microprocessor 8 is connected to a server 12, wherein data received from the microprocessor is analyzed and utilized for further use by the overall process control system 100 shown in FIG. 1 to control and manage the microprocessor(s). The microprocessor can receive input from more than one regulating device (microprocessors and/or transducers) at the plural inputs depicted by numeral 3.

As shown in FIG. 3, a flow diagram 300 illustrates general steps that can be taken by server 12 and a user to manage regulated process 2 in maintenance system 100. In step 36, server 12 monitors regulated process 2 by waiting for data from microprocessor 8. Server 12 receives data from microprocessor 8 in step 38 and processes the data in step 40. In step 42, server 12 diagnoses the operating status of regulated process 2 based on information known about regulated process 2 and parameters preset by a user. Server 12 subsequently determines if the diagnosis requires that action be taken to maintain the preset parameters. If server 12 determines that the operating status of regulated process 2 falls within the preset parameters, server 12 records the decision in database 16, as shown in step 44, and resumes monitoring as in step 36. If, in step 42, server 12 determines that the operating status of regulated process 2 falls outside of the parameters preset by a user, server 12 signals the problem in step 46 and records the signal transmission as in step 44. Upon discovery of the problem signaled in step 46, a user decides in step 48 if the problem requires action. If a user determines that the problem signaled in step 46 requires no action, then server 12 records the decision as in step 44 and resumes monitoring as in step 36. If a user determines that the problem signaled in step 46 does require action, then a user signals the necessary action to server 12 in step 50. In turn, server 12 records the decision as in step 44, executes the decision, and resumes monitoring as in step 36.

As shown in FIG. 4, a flow diagram 400 illustrates an example of more specific steps taken by maintenance system 100 in managing regulated process 2. In step 52, transducer 4 collects data from regulated process 2. Transducer 4 then sends the data to microprocessor 8 in step 54. In step 56, microprocessor 8 receives data sent from transducer 4 and processes the data by following a user- defined protocol. Microprocessor 8 sends the data to server 12 in step 58. In step 60, server 12 then diagnoses the operating status of regulated process 2 by following a protocol preset by a user. The protocol might include comparing the data received from microprocessor 8 with information known about regulated process 2 or with data stored in database 16. Information about regulated process 2 might include device specifications, process tolerances, life expectancies of particular components, warranty information, etc. Comparing such 'internal' data about regulated process 2 and/or components with operating data from processes can be used to inform a user, or recorded, of the operating status of the process or its associated components. Access to stored data would also permit a user to analyze trends in operating performance over time. In step 62, server 12 determines if the operating status falls within a user-defined range. For example, a user might define a safe operating range for the temperature of a particular zone in regulated process 2. If, in step 62, server 12 concludes that the operating status of regulated process 2 does not require that special action be taken, such as the zone temperature being within the safe range, server 12 records the decision in database 16 in step 64. Server 12 then resumes monitoring in step 66. If, in step 62, server 12 concludes that the operating status of regulated process 2 does require that special action be taken, such as in response to the zone overheating, server 12 follows in step 68 a protocol preset by a user to determine which specific action to take. Server 12 can decide to notify a user of the problem in step 70, possibly by sending an email or an electronic page, making a phone call, or displaying or sounding an alarm. Alternatively, server 12 might follow a protocol to activate, deactivate, or alter a process as shown in step 72, such as increasing the rotating speed of a motor or turning it off all together. Another option that server 12 could take might be to schedule maintenance, as shown in step 74, in order to maintain optimum performance of regulated process 2 or to prevent damage. After any such decision made in step 68, server 12 can record the decision in database 16 as in step 64, can follow the appropriate protocol(s) to execute the decision, and can resume monitoring as in step 66.

An example of a protocol that microprocessor 8 can follow using data received from transducer 4 is timing the duration of a user-designated event. A timer relay provides the means to time the duration of the event, which a user can select from a list of menu items. Time could be displayed as hours and minutes, days and hours, etc. The list of configurable menu items might include: operating a process for a user-specified time interval, timing the duration of a process in manual control, timing the duration of a calculated guaranteed soak band (a set point programming feature), timing the duration for which a calculated limit is exceeded (such as a sooting limit for combustion control), or timing the duration that user-specified digital inputs are active. Related to the timer relays is the ability to set an alarm, or other digital output, on a time-related condition. This feature might involve a set point value and would provide physical relay outputs so that the time of the ON/OFF states can control an automatic process-related function, such as the burn-off of probe contaminants every 30 days for a specified time duration.

Another example of a protocol that microprocessor 8 can follow is counting the number of occurrences of a user-designated event. A counter relay provides the means to count the occurrences of the event, which a user similarly selects from a list of menu options. The list of configurable menu items might include: counting the number of transitions to manual control, counting the transitions for multiple set point- related alarm events, counting the transitions associated with certain digital inputs for life expectancy data, counting the transitions out of the guaranteed soak band, counting the number of power cycles, counting the number of times that a specified range was exceeded (such as a PV range), counting the number of times regulated process 2 transitioned into failsafe control, or counting the number of times that any control tuning parameters were altered. Related to the counter relays and similar to the timer relays is the ability to set an alarm, or other digital output, on a set point value. This feature provides physical relay outputs that can be used to notify a user of an impending condition, such as the number of output relay transitions exceeding a user-designated set point value. The alert would provide advance notice of the adverse condition by indicating that preventive maintenance is required to replace the relay, which can be near the end of its rated life expectancy. In this respect, microprocessor 8 can not only monitor the operating status of regulated process 2, but the status of itself.

As shown in FIG. 5, a flow diagram 500 illustrates an example of more specific steps that might be taken by a user in managing regulated process 2 with maintenance system 100. In step 73, a user receives notification of a problem in the operating status of regulated process 2. As previously stated, the notification could be any number of alerts, such as a phone call, an email, or a visual or audible alarm. A user logs on to server 12 via network 24 in step 74 and gains access to server 12 in step 76 by providing proper user identification and a password. A user then monitors in step 78 either real-time data from regulated process 2 or data stored in database 16. Alternatively, a user can access server 12 locally using local user-controlled device 32, bypassing network 24, and monitor data as in step 78. In step 80, a user determines whether or not the situation requires subsequent action. If not, a user instructs server 12 to resume monitoring, shown in step 82, and then logs out, if necessary, in step 84. If a user determines that the situation does require special action in step 80, a user then decides in step 81 which specific action to take. A user can decide to program the server in step 86 or to activate, deactivate, or alter a process in step 88. Alternatively, a user can decide to schedule maintenance in step 90, to reset timer or counter relays in step 92, or to lock out unauthorized reconfiguration or resetting in step 94. A user can then resume monitoring data in step 82 and logs out, if necessary, in step 84 when finished.

The embodiments and examples set forth herein are presented to best explain the present invention and its practical application and to thereby enable those skilled in the art to make and utilize the invention. Those skilled in the art, however, will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. Other variations and modifications of the present invention will be apparent to those of skill in the art, and it is the intent of the appended claims that such variations and modifications be covered. The description as set forth is not intended to be exhaustive or to limit the scope of the invention. Many modifications and variations are possible in light of the above teaching without departing from the spirit and scope of the following claims. It is contemplated that the use of the present invention can involve components having different characteristics. It is intended that the scope of the present invention be defined by the claims appended hereto, giving full cognizance to equivalents in all respects.

Claims

CLAIMSThe embodiments of an invention in which an exclusive property or right is claimed are defined as follows:

1. A system for remote maintenance of a regulated device by a user, comprising: at least one microprocessor operatively coupled to at least one transducer integrated to a regulated device for measuring data from the regulated device, said at least one microprocessor for managing data received from transducers; a server connected to said at least one microprocessor for processing data received from said at least one microprocessor; and said server connected to a network for transmitting processed data from said server to remote user-controlled devices having access to said server over the network and receiving commands from remote user-controlled devices over the network, wherein a user can monitor the per ormance of a regulated device via the network and can selectively intervene to provide control of a regulated device.

2. The system of claim 1 , further comprising said server being connected to a database.

3. The system of claim 1 , wherein said server is connected to a network operating system.

4. The system of claim 1 , further comprising said server being directly connected to a local user-controlled device.

5. The system of claim 1 , further comprising said server being directly connected to a wireless user-controlled device.

6. The system of claim 1 , wherein said network is private.

7. The system of claim 1 , wherein said network is public.

8. A system for maintenance of regulated devices, comprising: a server for monitoring the operation of at least one regulated device wherein said server is programmable to alter parameters of the at least one regulated device; at least one microprocessor-controller connected to said server wherein said at least one microprocessor-controller functions as a control interface between said server and the at least one regulated device; a transducer operatively coupled to said at least one microprocessor- controller and integrated to the at least one regulated device for providing measurement data from the at least one regulated device to said at least one microprocessor; and said server further comprising access to a remote user-controlled device, wherein a user can monitor the operation of regulated devices and can program said server to alter parameters of regulated devices via remote user- controlled devices.

9. The system of claim 8, further comprising said server being connected to a network, wherein a user can access regulated devices via the network.

10. The system of claim 8, further comprising said server being connected to a wireless user-controlled device, wherein a user can access regulated devices via the wireless user-controlled device.

11. The system of claim 8, further comprising said server providing a user with real-time data from regulated devices.

12. The system of claim 8, wherein said server provides a user with stored data from regulated devices, wherein said data is stored in a database connected to said server.

13. The system of claim 8, wherein said at least one microprocessor accumulates data from regulated devices using a counting relay.

14. The system of claim 8, wherein said at least one microprocessor accumulates data from regulated devices using a timing relay.

15. The system of claim 8, wherein said server follows a protocol to notify a user if parameters of regulated devices have been or should be altered.

16. A network maintenance system for providing a user with real-time data from regulated devices, comprising: a server linked to a network for sending real-time data to and receiving instruction from a remote user-controlled device; at least one microprocessor connected to said server for executing commands from a user using a remote user-controlled device to alter parameters of at least one regulated device; and a transducer operatively coupled to said at least one microprocessor and integrated to at least one regulated device for converting data from the at least one regulated device to said at least one microprocessor, wherein a user operating a remote user-controlled device can monitor the performance of regulated devices with real-time data transmitted to the remote user-controlled device from said server via a network.

17. The system of claim 16, wherein said at least one microprocessor is programmable.

18. The system of claim 16, wherein said server provides a user with stored data from regulated devices, wherein said data is stored in a database connected to said server.

19. The system of claim 16, wherein said at least one microprocessor accumulates data from regulated devices using a counting relay.

20. The system of claim 16, wherein said at least one microprocessor accumulates data from regulated devices using a timing relay.

21. The system of claim 16, wherein said server follows a protocol to notify a user if parameters of regulated devices have been or should be altered.

22. A method for a user to monitor and maintain at least one regulated device via a network, including the steps of: logging on to a network with a remote user-controlled device; gaining access to a server via the network; reviewing data managed by said server for at least one regulated device; and sending instruction to said server via the network, wherein said instruction causes said server to alter parameters of said at least one regulated device.

23. The method of claim 22, further comprising the step of a user monitoring and maintaining said at least one regulated device with a local user-controlled device.

24. The method of claim 22, wherein said server notifies a user of the operating status of said at least one regulated device.