Commissioning and Configuring Control Electronics Associated with Assets

• US 20180040235A1
• Filed: 08/05/2016
• Published: 02/08/2018
• Est. Priority Date: 08/05/2016
• Status: Active Grant

• Current Assignee: epro GmbH (Emerson Electric Company)
• Original Assignee: epro GmbH (Emerson Electric Company)
• Inventors: Tegeder, Uwe, Wermers, Sven, Hermens, Hilmar
• Granted Patent: US 10,049,564 B2
• Time in Patent Office: Days
• CPC Class Codes: G08C 17/02 using a radio link
• CPC Class Codes: G08C 2201/20 Binding and programming of remote control devices
• CPC Class Codes: G08C 2201/93 Remote control using other portable devices, e.g. mobile phone, PDA, laptop
• CPC Class Codes: H04Q 2209/40 using a wireless architecture
• CPC Class Codes: H04Q 2209/50 using a mobile data collecting device, e.g. walk by or drive by
• CPC Class Codes: H04Q 9/00 Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom

Abstract

A mobile device is used in conjunction with control electronics and associated assets and sensors to facilitate the setup or modification of programming in the electronics. The mobile device is used to initially commission sensors by collecting data from the field, such as sensor identity, asset identity and measurement points, and uploading the collected data to the electronics. The mobile device may also be used to select programming in the control electronics for analyzing sensor signals from a particular sensor. The mobile device is also used to collect data from the field for use in linearizing sensor signals when they are received by the control electronics and to transmit maintenance commands to the control electronics thereby causing a programming change in the control electronics to prevent the transmission of a type of command or a type of information, such as a shutdown command or an alarm or alert.

Claims

1. An apparatus for monitoring assets comprising:

sensors disposed on the assets to produce sensor signals corresponding to characteristics of the assets;

control electronics connected to the sensors for receiving and analyzing the sensor signals and for transmitting information and commands;

a mobile device for communicating with the control electronics and sensors;

the mobile device having an input and being configured and programmed;

a. to receive on-site data from the input, the on-site data corresponding to sensor identity, asset identity and sensor signals,

b. to communicate the on-site data to the electronics, and

c. to produce and communicate mobile control signals to the control electronics based on user input provided through the input of the mobile device;

the control electronics being configured and programmed;

a. with asset data corresponding to the identities and locations of the sensors, identities of the assets, acceptable conditions of the assets, and abnormal conditions of the assets,

b. for analyzing the sensor signals and determining the condition of the assets based on the asset data,

c. for transmitting at least one of (1) commands and (2) information if a determined condition of an asset is an abnormal condition,

d. for receiving and analyzing the on-site data and the mobile control signals,

e. for modifying at least one of the (1) transmission of the commands and (2) the analysis of the sensor signals based on one or more of the on-site data and the mobile control signals.

2. The apparatus of claim 1 further comprising wireless transceivers for providing wireless communications between the mobile device and the electronics.

3. The apparatus of claim 1 further comprising:

indicia indicating a sensor identity provided on or proximate to one or more of the sensors; and

wherein the input of the mobile device includes an electronic input capable of reading the indicia and communicating the sensor identity to the mobile device.

4. The apparatus of claim 3 wherein the indicia is machine readable code, which may comprise an electronic chip.

5. The apparatus of claim 1 wherein the mobile device is further configured and programmed to initialize the function of the control electronics with respect to a particular asset by:

a. identifying the particular asset and one or more associated sensors, and

b. transmitting information to the control electronics providing the identity of the particular asset and the associated sensors.

6. The apparatus of claim 1 wherein the mobile device is further configured and programmed to initialize the function of the control electronics with respect to a particular asset by:

a. identifying the particular asset and one or more associated sensors,

b. transmitting information to the control electronics providing the identity of the particular asset and the associated sensors, and

c. configuring the control electronics to monitor the associated sensors of the particular asset.

7. The apparatus of claim 5 wherein:

a. the control electronics includes a plurality of microprocessor-based units programmed to monitor signals from the sensors; and

b. the mobile device is programmed to configure a particular unit to monitor the sensor signals of a sensor associated with the particular asset based on user inputs into the mobile device.

8. The apparatus of claim 5 wherein:

a. the mobile device is programmed to select a procedure for monitoring and analyzing sensor signals for a particular sensor in response to user input and to transmit the identity of the selected procedure and the identity of the particular sensor to the electronics; and

b. the control electronics is programmed with procedures for monitoring and analyzing sensor signals and is programmed to select a procedure and configure itself to analyze signals from the particular sensor based upon the procedure identity and the identity of the particular sensor transmitted from the mobile device.

9. The apparatus of claim 1 wherein:

a. a machine readable code is placed at each sensor location containing a number identifying the sensor and a code identifying a measurement point on an asset, and

b. the input of the mobile device includes a code reader for reading the machine readable code and determining the code identifying the sensor.

10. The apparatus of claim 1 wherein the mobile device is programmed to perform a sensor linearization function by:

a. storing a code identifying a particular sensor;

b. receiving and storing a plurality of sensor parameter values corresponding to a parameter being sensed by the particular sensor;

c. receiving and storing a plurality of sensor signal values corresponding to magnitudes of the sensor signal from the particular sensor at a plurality of times;

d. associating sensor parameter values with sensor signal values to produce a plurality of paired values;

e. storing the plurality of paired values in the mobile device; and

f. transmitting to the control electronics linearization information that (1) includes paired values or (2) includes information based upon the paired values;

wherein the control electronics is programmed to use the linearization information for linearizing the sensor signal from the particular sensor.

11. The apparatus of claim 1 wherein the mobile device and control electronics are programmed to perform a linearization function by:

identifying a plurality of sensors and storing the identities of the sensors in the mobile device to produce a sensor identification for each identified sensor;

receiving and storing a plurality of sensor parameter values and timestamps, each sensor parameter value being associated with a sensor identification and a timestamp;

storing a plurality of sensor identifications in the control electronics;

receiving and storing a plurality of sensor signal values and timestamps in the control electronics, each of the sensor signal values being associated with a timestamp and a sensor identification,

transmitting linearization data from the mobile device to the control electronics, the linearization data including the plurality sensor parameter values, an associated sensor identification for each sensor parameter value, and an associated timestamp for each sensor parameter value.

using the timestamps and sensor identifications associated with the sensor parameter values and the timestamps and sensor identifications associated with the sensor signal values to correlate the sensor parameter values with the sensor signal values and to thereby associate a sensor signal value with a sensor parameter value to produce a plurality of paired values for a plurality of sensor identifications; and

using the paired values to interpret the sensor signal from each identified sensor whereby the paired values are used linearize the correlation between sensor parameters and sensor signal values for each of the identified sensors.

12. The apparatus of claim 1 wherein the mobile device and the control electronics are configured to perform a linearization function by:

providing communication between the mobile device and the control electronics;

identifying a sensor with the mobile device and communicating the identity of the sensor from the mobile device to the control electronics;

receiving on the mobile device a plurality of parameter values for the sensor and transmitting each parameter value from the mobile device to the control electronics;

receiving at the control electronics a sensor signal from the sensor and storing a value of the sensor signal and a sensor parameter value that was received from the mobile device, so that a plurality of paired values are produced with each paired value containing a sensor parameter value and a sensor signal value; and

using the paired values for linearizing the correlation between sensor parameters and sensor signal values for the sensor.

13. The apparatus of claim 1 wherein:

a. the mobile device is programmed to produce a maintenance command associated with at least one asset as one of the mobile control signals, and

b. the control electronics is programmed to respond to the maintenance command by modifying the programming of the control electronics to prevent transmission of a particular type of command.

14. The apparatus of claim 13 wherein

a. the mobile device is programmed to produce a reactivation command associated with at least one asset as one of the mobile control signals,

b. the control electronics is programmed to respond to the reactivation command to allow the transmission of the particular type of command.

15. The apparatus of claim 13 wherein the particular type of command is a shut down command that will cause the operation of an asset to shut down.

16. An apparatus of claim 1 wherein the control electronics further comprise at least one of predictive maintenance electronics, protective electronics, monitoring control electronics and control electronics.

17. A method for monitoring assets comprising:

disposing sensors on the assets to produce sensor signals corresponding to characteristics of the assets;

receiving and analyzing the sensor signals with control electronics and transmitting information and commands based on analysis of the sensor signals;

communicating with the control electronics and sensors with a mobile device;

receiving on-site data into the mobile device, the data corresponding to sensor identity, asset identity and sensor signals;

communicating the on-site data from the mobile device to the electronics;

producing and communicating mobile control signals from the mobile device to the control electronics based on user input to the mobile device;

analyzing the sensor signals using the control electronics and determining the condition of the assets based on the asset data;

transmitting at least one of (1) commands and (2) information if a determined condition of an asset is an abnormal condition;

receiving and analyzing the on-site data and the mobile control signals with the electronics; and

modifying at least one of the (1) transmission of the commands and (2) the analysis of the sensor signal based on one or more of the on-site data and the mobile control signals.

18. The method of claim 17 further comprising:

using the mobile device to further configure and program the control electronics to initialize the control electronics with respect to a particular asset by;

a. identifying the particular asset and one or more associated sensors associated with the particular asset to produce the identity of the particular asset and the associated sensors;

b. transmitting information from the mobile device to the control electronics providing the identity of the particular asset and the associated sensors;

c. configuring the control electronics to monitor the associated sensors of the particular asset using the transmitted information.

19. The method of claim 17 further comprising:

storing a code identifying a particular sensor in the mobile device;

receiving and storing a plurality of sensor parameter values in the mobile device, the sensor parameter values corresponding to a parameter being sensed by the particular sensor;

recording a timestamp in association with each parameter value corresponding to the time at which each parameter value was created;

receiving and storing a plurality of sensor signal values and timestamps corresponding to the magnitudes of the sensor signal from the particular sensor at a plurality of times;

using the timestamps to associate stored sensor parameter values with stored sensor signal values to produce a plurality of paired values, each paired value including a sensor parameter value and a sensor signal value; and

using the paired values to configure the programming of the control electronics to linearize the sensor signal from the particular sensor.

20. The method of claim 17 further comprising:

producing a maintenance man with the mobile device and transmitting the maintenance command to the electronics; and

responding to the maintenance command to modify the programming of the control electronics to prevent the transmission of a particular type of command.