DIGITAL VALVE CONTROLLER

• US 20070005159A1
• Filed: 06/30/2006
• Published: 01/04/2007
• Est. Priority Date: 07/01/2005
• Status: Active Grant

• Current Assignee: Curtiss-Wright Flow Control Corporation (Curtiss-Wright Corporation)
• Original Assignee: Curtiss-Wright Flow Control Corporation (Curtiss-Wright Corporation)
• Inventors: Leib, Anthony, Venable, James, Borah, Frederic, Gavarian, Richard
• Granted Patent: US 7,636,613 B2
• Time in Patent Office: Days
• US Class Current: 700/83
• CPC Class Codes: G01R 31/2829 Testing of circuits in sensor or actuator systems testing of apparatus for measuring electric or magnetic variables G01R35/00; testing of indicating or recording apparatus G01D; in airbag systems B60R21/0173; checking gas analysers G01N33/007; monitoring or fail-safe circuits for electromagnets H01F7/1844
• CPC Class Codes: G05B 2219/24028 Explosion free control, intrinsically safe
• CPC Class Codes: G05B 9/02 electric

Abstract

A deterministic controller for an actuator includes, for example, adaptation for installation in an explosion-proof housing and a primary controller sealed within the housing for controlling outputs. A backup controller is optionally provided for alternatively controlling the outputs. An operator interface is provided on the housing for accepting operator inputs for providing to the controller. A display is provided on the housing for displaying an output of the controller. The controller includes means for monitoring for a failure of the primary controller if the optional backup controller is installed, and the controller is adapted for switching from the primary controller to the backup controller upon detecting the failure of the primary controller. The outputs can be user configured to desired output ranges from the operator interface without opening the housing. Furthermore, remote access and control of the controller is provided in a manner that most or all operator operations are available remotely, including a reproduction of data displayed on the controller display and means for entering data. Such remote access can be provided via the Internet. The controller also stores and can display event and fault lists.

Claims

1. A device for controlling an actuator, said device comprising:

a primary controller sealed within an explosion-proof housing and adapted for controlling one or more outputs connected to the actuator;

a backup controller mounted within the housing adapted for alternatively controlling said one or more outputs connected to the actuator;

an operator interface provided on an outer surface of the housing for accepting operator inputs for providing to one or both of said primary controller and said backup controller;

a display on said outer surface of the housing for displaying an output of one or both of said primary controller and said backup controller; and

means for monitoring for a failure of said primary controller;

wherein

said device is adapted for automatically switching from said primary controller to said backup controller upon detecting the failure of said primary controller, such that the functions of controlling of said one or more outputs, said providing of said operator inputs, and said displaying an output are all transferred from said primary controller to said backup controller upon said automatic switching.

2. The device of claim 1, wherein said controllers utilize a deterministic operating system.

3. The device of claim 1, further comprising:

a first power supply for supplying power to both said primary and said backup controllers; and

a second power supply for also supplying power to both said primary and said backup controllers, wherein

said device is adapted to automatically remain operable after the failure of either power supply.

4. The device of claim 1, wherein:

a current or voltage of said outputs is operator configurable; and

the housing has an opening sealed by a door, the door having said outer surface; and

further

said controller is adapted for setting said current or voltage of said outputs based on said operator settings without opening the door and thereby without breaking the seal formed by the door.

5. The device of claim 1, further comprising:

a data input interface for receiving data from the actuator and/or from other equipment being acted on by said actuator;

a memory for storing expected parameters of said actuator, wherein

said controller is adapted for comparing said data, and/or derived parameters of said data, with said expected parameters, to monitor a health and status of one or both of the actuator and the other equipment, and wherein

said controller is further adapted to indicate the health and the status to the operator or another operator.

6. The device of claim 5, wherein:

said controller is also adapted for determining an impending failure of one or both of the actuator and the other equipment based on said comparing, and

said controller further adapted for notifying the operator or another operator of the impending failure.

7. The device of claim 1, further comprising a door for providing access to said controllers.

8. A device provided in a housing having an opening sealed by a door, the door having an outer surface, said device for controlling an actuator, said device comprising:

a controller mounted within the housing adapted for controlling one or more outputs having variable current or voltage setup ranges are connected to the actuator for controlling an operation of the actuator, wherein said setup ranges are operator configurable;

an operator interface for accepting operator settings for input to said controller without opening the door; and

a display and/or indicator on said outer surface of the housing for displaying an output of said controller, wherein

said controller is adapted for configuring said setup ranges of said outputs based on said operator settings,

thereby configuring said output setup ranges without breaking the seal formed by the door.

9. The device of claim 8, wherein the housing is an explosion-proof housing.

10. The device of claim 8 wherein said operator interface is provided by a terminal connected to said device via a computer network, with said operator accessing said device remotely.

11. The device of claim 10, wherein said computer network is the Internet.

12. The device of claim 8 wherein said operator interface is provided on said outer surface of the housing.

13. A device for controlling an actuator, said device comprising:

a controller mounted within a housing having an outer surface, said controller being adapted for controlling one or more outputs connected to the actuator for controlling an operation of the actuator;

a data input interface for receiving data from the actuator and/or from other equipment being acted on by said actuator;

a memory for storing expected parameters of said actuator;

an operator interface provided on the outer surface of the housing for accepting operator commands and/or settings for input to said controller; and

a display and/or indicator on the outer surface of the housing for displaying an output of said controller, wherein

said controller is adapted for comparing said data, and/or derived parameters of said data, with said expected parameters, to monitor a health and status of one or both of the actuator and the other equipment, and wherein

said controller is further adapted to indicate the health and the status to the operator utilizing said display and/or indicator.

14. The device of claim 13 wherein:

said controller is also adapted for determining an impending failure of one or both of the actuator and the other equipment based on said comparing, and

said controller is further adapted for notifying the operator or another operator of the impending failure.

15. The device of claim 14 wherein said controller is also adapted for executing a pre-programmed test of the actuator for generating said data.

16. The device of claim 13 wherein said controller is also adapted for executing a pre-programmed test of the actuator for generating said data.

17. The device of claim 16 wherein said test is conducted without taking said actuator off-line.

18. The device of claim 17 wherein said test is a dynamic step response test.

19. The device of claim 13 wherein said health and status are indicated to a remote operator accessing said device via the Internet.

20. The device of claim 13, further comprising:

an additional controller; and

means for monitoring for a failure of said controller;

wherein

said device is adapted for automatically switching from said controller to said additional controller upon detecting the failure of said controller, such that the functions of said controlling of said one or more outputs, said providing of said operator inputs, and said displaying an output are all transferred from said controller to said additional controller upon said automatic switching.

21. A device for controlling an actuator, said device comprising:

a controller mounted within a housing having an outer surface, said controller being adapted for controlling one or more outputs connected to the actuator for controlling an operation of the actuator;

a data input interface for receiving data from the actuator and/or from other equipment being acted on by said actuator;

an operator interface including a plurality of input devices provided on the outer surface of the housing for accepting operator commands and/or settings for input to said controller; and

a display on the outer surface of the housing for displaying an output of said controller, wherein

said controller is adapted for serving data to a remote terminal, operated by a remote operator, said remote terminal connected to said device via a computer network and adapted to receive said served data in order to;

reproduce graphically said display on a display of the remote terminal for viewing by a remote operator of said remote terminal such that the remote operator can view said output of said controller, and

reproduce or emulate said operator interface on said remote terminal for said remote operator entering said operator commands and/or settings for input to said controller from the remote location.

22. The device of claim 21, wherein said computer network includes the Internet.

23. The device of claim 21, further comprising:

an additional controller; and

means for monitoring for a failure of said controller;

wherein

said device is adapted for automatically switching from said controller to said additional controller upon detecting the failure of said controller, such that said controlling of said one or more outputs, said providing of said operator inputs, and said output for display are all transferred from said controller to said additional controller upon said automatic switching.

24. A device for controlling an actuator, said device comprising:

a controller mounted within a housing having an outer surface, said controller being adapted for controlling one or more outputs connected to the actuator for controlling an operation of the actuator;

a data input interface for receiving data from the actuator and/or from other equipment being acted on by said actuator;

operator interface including a plurality of input devices provided on the outer surface of the housing for accepting operator commands and/or settings for input to said controller; and

a display on the outer surface of the housing for displaying an output of said controller, wherein

said controller is adapted for recording a plurality of events and faults based on the operation of two or more of the device, the actuator, and the other equipment, and wherein

said events and faults can be displayed to an operator utilizing the display in a manner allowing the operator to browse said events and faults.

25. The device of claim 24, wherein said events and faults are transmitted to a remote terminal, via a computer network, for allowing a remote operator to browse said events and faults using the remote terminal.

26. The device of claim 24, further comprising:

an additional controller; and

means for monitoring for a failure of said controller;

wherein

said device is adapted for automatically switching from said controller to said additional controller upon detecting the failure of said controller, such that the functions of said controlling of said one or more outputs, said providing of said operator inputs, and said displaying an output are all transferred from said controller to said additional controller upon said automatic switching.